Total productive maintenance

In industry, total productive maintenance (TPM) is a system of maintaining and improving the integrity of production and quality systems through the machines, equipment, processes, and employees that add business value to an organization.

TPM focuses on keeping all equipment in top working condition to avoid breakdowns and delays in manufacturing processes.

The term total productive maintenance is attributed to Nippondenso, a company that created parts for Toyota. However, Seiichi Nakajima is regarded as the father of TPM because of his numerous contributions to TPM.

One of the main objectives of TPM is to increase the productivity of plant and equipment with a modest investment in maintenance. Total quality management (TQM) and total productive maintenance (TPM) are considered as the key operational activities of the quality management system. In order for TPM to be effective, the full support of the total workforce is required. This should result in accomplishing the goal of TPM: "Enhance the volume of the production, employee morale and job satisfaction."

The main objective of TPM is to increase the Overall Equipment Effectiveness of plant equipment. TPM addresses the causes for accelerated deterioration while creating the correct environment between operators and equipment to create ownership.

OEE has three factors which are multiplied to give one measure called OEE
Performance x Availability x Quality = OEE

Each factor has two associated losses making 6 in total, these 6 losses are as follows:

Performance = (1) running at reduced speed - (2) Minor Stops

Availability = (3) Breakdowns - (4) Product changeover

Quality = (5) Startup rejects - (6) Running rejects

The objective finally is to identify then prioritize and eliminate the causes of the losses. This is done by self-managing teams that problem solve. Employing consultants to create this culture is common practice.

The eight pillars of TPM are mostly focused on proactive and preventive techniques for improving equipment reliability:

With the help of these pillars we can increase productivity. Manufacturing support.

Following are the steps involved by the implementation of TPM in an organization:

- Initial evaluation of TPM level,

- Introductory Education and Propaganda (IEP) for TPM,

- Formation of TPM committee,

- Development of master plan for TPM implementation,

- Stage by stage training to the employees and stakeholders on all eight pillars of TPM,

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