Total Productive Maintenance (TPM)

Total Productive Maintenance
Lean Manufacturing Series

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Overview
• What is Total Productive Maintenance
• Origins of TPM
• TPM Principles
• Components of TPM
▫ Autonomous Maintenance
▫ Planned Maintenance
▫ Equipment & Process Improvement
▫ Early Management of New Equipment
▫ Process Quality Management
▫ TPM in the Office
• Implementing TPM
• TPM Benefits
• Maintenance Management & Strategy
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What is TPM

• A company-wide team-based effort to build quality into
equipment and to improve overall equipment
effectiveness
• Total
▫ all employees are involved
▫ it aims to eliminate all accidents, defects and
breakdowns
• Productive
▫ actions are performed while production goes on
▫ troubles for production are minimized
• Maintenance
▫ keep in good condition
▫ repair, clean, lubricate
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Autonomous Maintenance
• 7 steps are implemented to progressively increase
operators knowledge, participation and responsibility
for their equipment
1. Perform initial cleaning and inspection
2. Countermeasures for the causes and effects of dirt
and dust
3. Establish cleaning and lubrication standards
4. Conduct general inspection training
5. Carry out equipment inspection checks
6. Workplace management and control
7. Continuous improvement

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Early Management of New Equipment

• Objective: establish systems to shorten
▫ new product or equipment development
▫ start-up, commissioning and stabilization time for
quality and efficiency
• New equipment needs to be:
▫ easy to operate
▫ easy to clean
▫ easy to maintain and reliable
▫ have quick set-up times
▫ operate at the lowest life cycle cost

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7: Develop 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

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Strategic Importance of Maintenance and Reliability

• Failure has far reaching effects on a firm’s
▫ operation
▫ reputation
▫ profitability
▫ customers
▫ product
▫ employees
▫ profits

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Tactics for Reliability and Maintenance

• Reliability Tactics
▫ improving individual components
▫ providing redundancy
• Maintenance Tactics
▫ implementing preventive maintenance
▫ increasing repair capabilities

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Organizing the Maintenance Function

• Centralized maintenance department
▫ Does all maintenance (PM & breakdown)
• Decentralized maintenance department
▫ Useful if different equipment used in different areas
of company
• Contract maintenance
▫ Used if little equipment or expertise
• Operator ownership approach

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Increasing Repair Capabilities:

Features of a Good Maintenance Facility
• Well-trained personnel
• Adequate resources
• Ability to establish a repair plan and priorities
• Ability and authority to do material planning
• Ability to identify the cause of breakdowns
• Ability to design ways to extend MTBF

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Total Productive Maintenance (TPM)

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