In a nutshell: Total Productive Maintenance (TPM) is a methodology designed to integrate equipment maintenance as a part of the standard operating procedures of the manufacturing process.
Use: The goal of a TPM program is to reduce or eliminate losses resulting from unplanned downtime.
Summary: Total Productive Maintenance focuses on reducing the amount of downtime for equipment, one of the biggest sources of revenue loss for most businesses. TPM calls for integrating maintenance as part of the operation of equipment.
The strategies and techniques employed in Total Productive Maintenance seek to make organizations proactive rather than reaction in how they approach maintenance issues. Benefits of using TPM include
- Lower repair costs
- Less equipment downtime
- Better productivity
- Increased employee satisfaction
- Reduced customer complaints
- Improved quality of products and services
Implementing Total Production Quality
TPM implementation starts with a strong foundation in 5S, a strategy that involves taking five steps to improve workstations and maintain those improvements, such as having all tools visible and within easy reach. The term “5S” comes from the names used for each phase of the system.
- Seiri (Sort)
- Seiton (Straighten or Set in Order)
- Seiso (Shine)
- Seiketsu (Standardize)
- sh*tsuke (Sustain)
With a strong 5S foundation in place, businesses that use TPM put The Eight Pillars of Total Production Maintenance in place.
Autonomous Maintenance:Putting routine maintenance in the hands of operators, including cleaning, lubricating and inspection.
Planned Maintenance:Using predicted failure rates determined by analysis of past performance to create a maintenance schedule designed specifically for each piece of equipment.
Quality Maintenance:Using root cause analysis to integrate design error detection and prevention into production processes.
Focused Improvement:Assigning small groups to work proactively, achieving regular, incremental improvements in equipment operation.
Early Equipment Management:Using knowledge gained through TPM to design new equipment.
Training and Education:Train operators, maintenance personnel and managers on what they need to know to achieve TPM goals.
Safety, Health, Environment:Considering the need to maintain a safe and healthy working environment for employees when making decisions on maintenance changes.
TPM in Administration:To make the biggest impact, organizations should also incorporate TPM into administrative functions.
FAQs
Total Productive Maintenance (TPM) is a methodology designed to integrate equipment maintenance as a part of the standard operating procedures of the manufacturing process. The goal of a TPM program is to reduce or eliminate losses resulting from unplanned downtime.
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.
How do you calculate total productive maintenance? ›
The best way to measure TPM is by calculating Overall Equipment Effectiveness (OEE). Availability is measured as 100% minus the following: Time losses related to equipment failure, Time losses related to adjustments and set-up, and.
What is total productive maintenance best described as quizlet? ›
Total Productive Maintenance performance utilizes the Overall Equipment Effectiveness (OEE) metric to characterize the overall performance of a single piece of equipment or even an entire factory.
What is Total Productive Maintenance? ›
Total productive maintenance (TPM) is a strategy that operates according to the idea that everyone in a facility should participate in maintenance, rather than just the maintenance team. This approach uses the skills of all employees and seeks to incorporate maintenance into the everyday performance of a facility.
Which of the following describes Total Productive Maintenance? ›
TPM (Total Productive Maintenance) is a holistic approach to equipment maintenance that strives to achieve perfect production: No Breakdowns. No Small Stops or Slow Running.
What are the 5 S of TPM? ›
The purpose of laying this foundation is to introduce standardization and continuous improvement processes into every TPM activity.
- Sort. ...
- Systemize. ...
- Shine. ...
- Standardize. ...
- Sustain. ...
- Pillar 1: Autonomous maintenance. ...
- Pillar 2: Planned maintenance. ...
- Pillar 3: Quality integration.
Total Productive Maintenance Examples
Machine operators do routine cleaning, greasing, lubrication, inspections, and replacing parts. They also identify and document inspection points. Plant personnel clean their work area, removing unused tools, debris, and anything that can be considered waste.
What is the TPM technique? ›
Total Productive Maintenance (TPM) seeks to engage all levels and functions in an organization to maximize the overall effectiveness of production equipment. This method further tunes up existing processes and equipment by reducing mistakes and accidents.
What are the 4 stages of TPM? ›
The Four Phases of TPM
- Stabilize current state and restore equipment.
- Measure the Six Big Losses.
- Eliminate losses.
- Improve design.
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.
What are the four zeros of TPM? ›
TPM: meaning
Total Productive Maintenance (TPM) is a methodology applied to maintenance management, which focuses on: prevention (zero accidents, zero breakdowns, zero defects, and zero equipment failure), optimization of the equipment, maximum production.
What is the main priority of TPM? ›
The major goal of the TPM approach is achieving a condition sometimes referred to as "perfect production." In other words, any manufacturer considering TPM aims to achieve zero defects, breakdowns or accidents.
How to measure TPM effectiveness? ›
One of the most common and comprehensive metrics to evaluate TPM performance is the overall equipment effectiveness (OEE). OEE measures how well your equipment is utilized and how much value it adds to your production. It is calculated by multiplying three factors: availability, performance, and quality.
What is the difference between TPM and OEE? ›
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.
What are the five goals of Total Productive Maintenance? ›
Goals of TPM
- No to fewer breakdowns.
- Safer environment and workspace.
- Faster speed.
- No to fewer defects or accidents.
- Better performance.
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.
What are the three elements of maintenance? ›
There are three major elements that make up a maintenance system; risk assessment, maintenance strategy selection and maintenance task interval determination.
What are the 5 pillars of Total Productive Maintenance? ›
The concept of restoring equipment to prime operating condition revolves around the 5-S system and autonomous maintenance. First, TPM participants should learn to continuously keep equipment to its original condition using the 5-S system: organize, cleanliness, orderliness, standardize and sustain.
What is the difference between Six Sigma and TPM? ›
One TPM pillar is dedicated to focused improvement through application of DMAIC and other problem-solving tools. On the other hand, TPM methodologies like cleaning, inspection and alignment are key components when a Lean Six Sigma project on an equipment gets to the Improve and Control phases of the project.
Total Productive Maintenance is a Lean philosophy that aims to achieve perfect production. That means no breakdowns, defects, accidents, or delays. It also encourages employees to take ownership of their machinery and, in turn, improve productivity, efficiency, and safety standards.
What is toc in Six Sigma? ›
The premise of the theory of constraints is that organizations can measure and control variations based on three factors: throughput, operational expense, and inventory. According to the Theory of Constraints, the goal of a company is to make money. Most constraints are NOT physical.
