ArtsAutosBooksBusinessEducationEntertainmentFamilyFashionFoodGamesGenderHealthHolidaysHomeHubPagesPersonal FinancePetsPoliticsReligionSportsTechnologyTravel

Total Productive Maintenance Implementation

Updated on October 13, 2009

TPM Implementation 12 Steps

Total Productive Maintenance Implementation: 12 Steps
Total Productive Maintenance Implementation: 12 Steps

Step 1: Announce top management’s decision to introduce TPM

  • State TPM objectives in a company newsletter
  • Place articles on TPM in the company newspaper


Step 2: Introductory education campaign

  • Seminars for managers
  • Slide presentations for all employees


Step 3: TPM Promotion

  • Special committees at every level to promote TPM
  • Newsletters
  • Articles
  • Videos
  • Posters


Step 4: Establish basic TPM policies and goals

  • Analyze existing conditions
  • Set goals
  • Predict results


Step 5: Preparation and Formulation of a master plan

  • A master plan lays out your goals, what you will do to achieve them and when you will achieve them
  • Detailed plans for each pillar have to be prepared 


Step 6: TPM kick-off

  • The main kick-off to TPM should take the form of a formal presentation with all the  employees attending
  • This opportunity can be used to gain the full support of the employees
  • Invite external customers, affiliated and subcontracting companies


Step 7: Develop an equipment management program

  • The tools of Total Quality Management and Continuous Improvement are applied to the management and improvement of equipment
  • Form project teams
  • Select model equipment
    - identify equipment problems
    - analyze equipment problems
    - develop solutions and proposals for improvement
  • Typical membership of a team
    - five to seven operators
    - a maintenance person
    - a technical expert
  • Tools
    - Pareto
    - Cause & effect
    - Root cause
    - Methods Analysis


Step 8: Develop a planned maintenance program

  • Set up plans and schedules to carry out work on equipment before it breaks down, in order to extend the life of the equipment
  • Include periodic and predictive maintenance
  • Include management of spare parts and tools


Step 9: Develop an autonomous maintenance program

  • A handing-over of maintenance tasks from specialized maintenance personnel to production operators
  • Tasks to hand over
    - cleaning
    - lubricating
    - inspecting
    - set-up and adjustment


Step 10: Increase skills of production and maintenance personnel

  • The training sessions must be planned shortly after the kick-off presentation
  • 2 major components
    - soft skills training
    - technical training
  • Train leaders together
  • Have leaders share information with group members


Step 11: Develop early equipment management program

  • The principle of designing for maintenance prevention can be applied to new products, and to new and existing machines
  • New products must be designed so that they can be easily produced on new or existing machines
  • New machines must be designed for easier operations, changeover and maintenance
  • Existing machines:
    - analyze historical records for
         - trends of types of failures
         - frequency of component failures
         - root causes of failures
    - determine how to eliminate the problem and reduce maintenance through an equipment  design change or by changing the process


Step 12: Perfect TPM implementation and raise TPM levels

  • Evaluate for the PM Award: The Japanese Institute for Productive Maintenance runs the annual PM Excellence Award. They provide a checklist for companies applying for the award
  • Set higher goals

More information about TPM - Total Productive Maintenance - is available at



    0 of 8192 characters used
    Post Comment

    • profile image


      4 years ago

      I like this post, enjoyed this one regards for posting. He removes the greatest ornament of friendship, who takes away from it respect. by Cicero. fgbekgffdeeb

    • profile image

      TPM COACH 

      6 years ago

      Is great this.

      Now in tpm have 7 steps like that fiat group

      best regards

    • profile image


      8 years ago

      Very interesting outline for implementation of this process.

    • seyiari profile image


      9 years ago


    • profile image


      9 years ago

      can u eloborate why external customers are invited.what will be their contribution in TPM.(Step-6)

    • profile image

      J. Ombogo 

      9 years ago

      Involving operators for machine condition monitoring is very important and this assist in eliminating any impending failure before failure occurs.


    • profile image

      joao assis 

      9 years ago

      Great job. I`m waiting for Lean steps implementation.



    This website uses cookies

    As a user in the EEA, your approval is needed on a few things. To provide a better website experience, uses cookies (and other similar technologies) and may collect, process, and share personal data. Please choose which areas of our service you consent to our doing so.

    For more information on managing or withdrawing consents and how we handle data, visit our Privacy Policy at:

    Show Details
    HubPages Device IDThis is used to identify particular browsers or devices when the access the service, and is used for security reasons.
    LoginThis is necessary to sign in to the HubPages Service.
    Google RecaptchaThis is used to prevent bots and spam. (Privacy Policy)
    AkismetThis is used to detect comment spam. (Privacy Policy)
    HubPages Google AnalyticsThis is used to provide data on traffic to our website, all personally identifyable data is anonymized. (Privacy Policy)
    HubPages Traffic PixelThis is used to collect data on traffic to articles and other pages on our site. Unless you are signed in to a HubPages account, all personally identifiable information is anonymized.
    Amazon Web ServicesThis is a cloud services platform that we used to host our service. (Privacy Policy)
    CloudflareThis is a cloud CDN service that we use to efficiently deliver files required for our service to operate such as javascript, cascading style sheets, images, and videos. (Privacy Policy)
    Google Hosted LibrariesJavascript software libraries such as jQuery are loaded at endpoints on the or domains, for performance and efficiency reasons. (Privacy Policy)
    Google Custom SearchThis is feature allows you to search the site. (Privacy Policy)
    Google MapsSome articles have Google Maps embedded in them. (Privacy Policy)
    Google ChartsThis is used to display charts and graphs on articles and the author center. (Privacy Policy)
    Google AdSense Host APIThis service allows you to sign up for or associate a Google AdSense account with HubPages, so that you can earn money from ads on your articles. No data is shared unless you engage with this feature. (Privacy Policy)
    Google YouTubeSome articles have YouTube videos embedded in them. (Privacy Policy)
    VimeoSome articles have Vimeo videos embedded in them. (Privacy Policy)
    PaypalThis is used for a registered author who enrolls in the HubPages Earnings program and requests to be paid via PayPal. No data is shared with Paypal unless you engage with this feature. (Privacy Policy)
    Facebook LoginYou can use this to streamline signing up for, or signing in to your Hubpages account. No data is shared with Facebook unless you engage with this feature. (Privacy Policy)
    MavenThis supports the Maven widget and search functionality. (Privacy Policy)
    Google AdSenseThis is an ad network. (Privacy Policy)
    Google DoubleClickGoogle provides ad serving technology and runs an ad network. (Privacy Policy)
    Index ExchangeThis is an ad network. (Privacy Policy)
    SovrnThis is an ad network. (Privacy Policy)
    Facebook AdsThis is an ad network. (Privacy Policy)
    Amazon Unified Ad MarketplaceThis is an ad network. (Privacy Policy)
    AppNexusThis is an ad network. (Privacy Policy)
    OpenxThis is an ad network. (Privacy Policy)
    Rubicon ProjectThis is an ad network. (Privacy Policy)
    TripleLiftThis is an ad network. (Privacy Policy)
    Say MediaWe partner with Say Media to deliver ad campaigns on our sites. (Privacy Policy)
    Remarketing PixelsWe may use remarketing pixels from advertising networks such as Google AdWords, Bing Ads, and Facebook in order to advertise the HubPages Service to people that have visited our sites.
    Conversion Tracking PixelsWe may use conversion tracking pixels from advertising networks such as Google AdWords, Bing Ads, and Facebook in order to identify when an advertisement has successfully resulted in the desired action, such as signing up for the HubPages Service or publishing an article on the HubPages Service.
    Author Google AnalyticsThis is used to provide traffic data and reports to the authors of articles on the HubPages Service. (Privacy Policy)
    ComscoreComScore is a media measurement and analytics company providing marketing data and analytics to enterprises, media and advertising agencies, and publishers. Non-consent will result in ComScore only processing obfuscated personal data. (Privacy Policy)
    Amazon Tracking PixelSome articles display amazon products as part of the Amazon Affiliate program, this pixel provides traffic statistics for those products (Privacy Policy)