Total productive maintenance, also known as TPM, is a proactive equipment maintenance program that has always been a part of Lean manufacturing. It started being applied in Six Sigma slowly but steadily, and now is widely used as Six Sigma control phase tool. A total or comprehensive approach to maintenance can be used to sustain improvements and control the improved Six Sigma process by removing deficiencies from machines to minimize or eliminate defects and downtime.
TPM is a proactive approach with the goal of removing deficiencies from machines to minimize or eliminate defects and downtime. It’s a unique concept for maintenance programs that aims to prevent deterioration and reduce maintenance; it’s not just about fixing equipment. TPM extends beyond simple preventive maintenance and includes comprehensive management of people, processes, systems, and the environment.
TPM promotes coordinated group activities for greater equipment effectiveness. Such activities include operators sharing responsibility for routine equipment inspection, cleaning, maintenance, and minor repairs. Also, as a part of the manufacturing day, downtime is scheduled for maintenance. In fact, it can be an integral part of the manufacturing process.
The goal of TPM is to increase production while also boosting workers’ job satisfaction and morale. Employees are empowered to take ownership and pride in maximizing the life and use of the equipment they operate, and reducing costs in the process. They then have end to end accountability. TPM focuses on maintenance as a necessary and vital component of the business.
A TPM program has three major features:
- it’s a system of productive maintenance to maximize the useful life of equipment
- the goal is to maximize equipment use and effectiveness
- it works through sharing responsibility for routine inspection, cleaning, maintenance, and minor repairs
The “total” in “total productive maintenance” encompasses total efficiency and effective use of equipment. This is a total package for both downtime prevention and maintenance maintainability, and – perhaps most importantly – the total participation of employees.
Key features of TPM
A TPM program focuses on a guiding principle of shared responsibility for maintenance. In support of this principle of shared responsibility, TPM includes three points:
- it has the involvement of employees at every level and across departments
- it integrates autonomous maintenance into the daily routine of operators
- it incorporates company-led small group activities to monitor the use of TPM throughout the organization
The goals of TPM
TPM is based on a “zero-loss” concept. This concept will allow you to achieve high reliability and flexibility of equipment. It also helps to reduce costs by minimizing wastage of manpower, raw material, energy, consumables, and so forth. TPM is accomplished through four specific objectives:
- zero breakdowns
- zero defects
- eliminating failures and waste due to equipment-related operations
- reducing emergency and unscheduled maintenance events to a minimum
There are six big losses that contribute negatively to equipment effectiveness. These are equipment failure, setup and adjustment time, machine idling and minor stoppages, reduced speed, process defects, and reduced yield.
The benefits of TPM
Eradicating or minimizing the six losses can dramatically improve operating conditions in your manufacturing plant. After all, losses such as equipment downtime can bring a Lean manufacturing operation to a complete standstill. The failure of equipment at one step of a process can strangle the flow entirely, halting all the steps before and after it as well. Properly integrating TPM will result in organizational benefits that are comprehensive:
- increased productivity and efficiency through improved worker and equipment utilization
- reduced of costs and inventory
- reduced accidents and pollution
- increased employee morale through a sense of ownership, mutual goals, shared knowledge and experience, and a collaborative work environment
- enhanced employee skills
Unexpected equipment downtime can destroy a business. Total productive maintenance, or TPM, is a proactive approach that emphasizes shared responsibility and focuses on preventing losses before they occur. With proper training, autonomous maintenance, which is a key aspect of TPM, empowers workers to take care of the equipment and machines they work with. The goal of TPM is the elimination of losses – including equipment breakdowns, idling and minor stoppages, defects and rework, and reduced speed – and the minimization of setup and yield losses. The implementation of TPM leads to improved utilization of production assets and plant capacity.