Total Productive Maintenance Certification - Management and Strategy Institute (2024)

FAQs

What do total productive maintenance TPM practices ensure select an answer? ›

TPM refers to the idea that operators are responsible for cleaning, maintaining, and improving their workstations to ensure safety and quality during production cycles. With TPM, the goal is to keep equipment working in optimal condition so that production processes move smoothly without breakdowns or delays.

The traditional approach to TPM was developed in the 1960s and consists of 5S as a foundation and eight supporting activities (sometimes referred to as pillars). The traditional TPM model consists of a 5S foundation (Sort, Set in Order, Shine, Standardize, and Sustain) and eight supporting pillars.

To measure overall equipment effectiveness, a TPM index, Overall Equipment Effectiveness (OEE) is used. OEE is calculated by multiplying (each as a percentage), overall equipment availability, performance and product quality rate.

The check sheets list areas to inspect on each machine, including cleaning the machine, lubricating moving parts, checking for abnormal sounds, and tightening nuts and bolts. Operators are to sign off after completing the CLIA checks each day.

The primary goal of TPM is to ensure Overall Equipment Effectiveness (OEE). OEE is a measure of the equipment's efficiency and is calculated as a product of asset availability, performance, and quality. When OEE is 100%, it means that the equipment is functioning at optimal capacity.

With the first 4 TPM Pillars (Autonomous Maintenance, Maintenance Improvement, Focused Improvement and Training and Skills Development) in place and taking hold, the TPM effort begins to focus on Quality Maintenance and achieving zero defects. Like safety, quality is everyone's responsibility.

Total productive maintenance (TPM) is the process of maximizing equipment effectiveness through the active involvement of all supporting departments. The goal of TPM is to improve overall productivity by optimizing equipment availability.

The eight pillars of TPM include early equipment management, focused improvement, autonomous maintenance, education and training, planned maintenance, quality maintenance, safety and health, and TPM in administration.

Overall Equipment Effectiveness (OEE) is a one of the key measures of TPM which indicates how effectively the machinery and equipment is being run. TPM aims to increase productivity by reducing lost production time, increasing available time for production and therefore output from the process.

TPM is a lean manufacturing philosophy that centres on achieving near-perfect production. The aims of TPM are high: no breakdowns, no small stops or slow running, no defects, and no accidents. It emphasises proactive and preventative maintenance to maximise the lifespan and productivity of equipment.

What is the TPM master plan? ›

A TPM Master Plan is a document that describes the activities, objectives, and timelines for developing comprehensive TPM capabilities in an organization.

Tools and Techniques used in TPM

Root Cause Analysis: A problem-solving technique used to identify the underlying cause of equipment problems and prevent recurrence. Data Analysis: Using data to identify patterns and trends that can be used to improve equipment performance and prevent downtime.

Findings: The commitment and involvement of the top management, i.e., the leadership team, is the most critical success factor in the successful implementation of TPM. Employee training is another vital factor.

1. Increased Equipment Efficiency and Reduced Downtime: TPM emphasizes preventive and predictive maintenance, which ensures that machinery and equipment are kept in peak operating condition. This reduces the incidence of breakdowns and unplanned stoppages.

Total productive maintenance (TPM) is a method used to boost the company's production, equipment efficiency by minimizing downtime. By implementing the TPM strategy, it's possible to see maintenance costs drop 25-30% and conversion costs decline by 20-25% over five years.

The goal of TPM is to improve overall productivity and quality by optimizing equipment availability and performance. TPM is built on the 5S methodology, a workforce organization technique that helps to streamline and standardize facility procedures.

TPM works by providing employees with the ability and skill to maintain their equipment, preventing problems early on, and handling them effectively and quickly once they arise. TPM focuses on perfect production by reducing or eliminating breakdowns, defects, accidents, and stops.