WHAT IS TPM?

DEFINITION: TPM IS TOTAL PRODUCTIVE MAINTENANCE/

TOTAL PROFIT MANAGEMENT,

AIM: TPM is a) Equipment by

CHANGE b) People to change the
c) Organization
A TPM program has three major features:
1. it’s a system of productive maintenance to maximize the useful life of equipment
2. the goal is to maximize equipment use and effectiveness
3. it works through sharing responsibility for routine inspection, cleaning, maintenance, and
minor repairs

T -------- total efficiency and effective use of equipment

P -------- Profit
M -------- Management

GOALS of TPM:
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

OBJECTIVES of TPM :
The main objective of TPM is to increase the Overall Equipment Effectiveness (OEE) of plant equipment.

Key Measures of TPM:

1. zero breakdowns
2. zero defects
3. eliminating failures and waste due to equipment-related operations
4. reducing emergency and unscheduled maintenance events to a minimum
The Benefits of TPM:
Properly integrating TPM will result in organizational benefits that are comprehensive:

1. increased productivity and efficiency through improved worker and equipment utilization,
2. reduced of costs and inventory
3. reduced accidents and pollution
4. increased employee morale through a sense of ownership, mutual goals, shared knowledge
and experience, and a collaborative work environment
5. enhanced employee skills
TQM is based on five cornerstones:
The product,
the process that allows the product to be produced,
the organization that provides the proper environment needed for the process to work,
the leadership that guides the organization, and
commitment to excellence throughout the organization.[9]

TQM focuses on the quality of the product,

while TPM focuses on the equipment used to produce the products.
By preventing equipment break-down,
improving the quality of the equipment and
by standardizing the equipment the quality of the products increases.
(results in less variance, so better quality),

TQM and TPM can both result in an increase of quality.

TPM implementation plan (12 steps):

Step 1: Announcement of TPM - Top management needs to create an environment that will support the introduction of
TPM. Without the support of management, skepticism and resistance will kill the initiative.
Step 2: Launch a formal education program. This program will inform and educate everyone in the organization about TPM
activities, benefits, and the importance of contribution from everyone.
Step 3: Create an organizational support structure. This group will promote and sustain TPM activities once they begin.
Team-based activities are essential to a TPM effort. This group needs to include members from every level of the
organization from management to the shop floor. This structure will promote communication and will guarantee everyone is
working toward the same goals.
Step 4: Establish basic TPM policies and quantifiable goals. Analyze the existing conditions and set goals that are SMART:
Specific, Measurable, Attainable, Realistic, and Time-based.
Step 5: Outline a detailed master deployment plan. This plan will identify what resources will be needed and when for
training, equipment restoration and improvements, maintenance management systems and new technologies.
Step 6: TPM kick-off. Implementation will begin at this stage.
Step 7: Improve effectiveness of each piece of equipment. Project Teams will analyze each piece of equipment and make
the necessary improvements.
Step 8: Develop an autonomous maintenance program for operators. Operators routine cleaning and inspection will help
stabilize conditions and stop accelerated deterioration.
Step 9: Develop a planned or preventive maintenance program. Create a schedule for preventive maintenance on each
piece of equipment.
Step 10: Conduct training to improve operation and maintenance skills. Maintenance department will take on the role of
teachers and guides to provide training, advice, and equipment information to the teams.
Step 11: Develop an early equipment management program. Apply preventive maintenance principles during the design
process of equipment.
Step 12: Continuous Improvement - As in any Lean initiative the organization needs to develop a continuous improvement
mindset.
 JH / AUTONOMOUS MAINTENANCE STEPS

Step 0= INPUT
Machine Component
Sheet
Step 0= OUTPUT
One Point Lesson

Step 0 Education - Machine Function

1. The Japanese Definition of TPM
•(By Siiechi Nakajima - the father of TPM - and vice chairman of the Japanese Institute
of Plant Maintenance JIPM)
•"TPM is a system of maintenance covering the entire life of the equipment in every
division including planning, manufacturing, and maintenance."
•TPM is characterized by 5 key elements:
a.TPM aims to maximize equipment effectiveness.
b.TPM establishes a thorough system of Preventive Maintenance (PM) for
the equipment’s entire life span.
c. TPM is cross-functional, implemented by various departments
(engineering, operators, maintenance, managers).
d. TPM involves every single employee.
e. TPM is based on the promotion of Preventive Maintenance through the motivation
of management and autonomous Small GroupActivity (SGA).
•The Japanese approach emphasizes the role of teamwork, small group activities and
the participation of all employees in the TPM process to accomplish
equipment improvement objectives.
3. Revised definition of TPM by JIPM 1996
•A broader application of TPM towards company-wide productivity.
•"TPM aims at:
a.Establishing a corporate culture that will Maximize Production system Effectiveness.
b.Organizing a practical shop-floor system to Prevent Losses before they occur
throughout the entire production system Life Cycle, with a view to achieving:
•zero Accidents,
•zero Defects and
•zero Breakdowns.
c.Involving all the functions of an organization including production, development,
sales and management.
d.Achieving zero losses through the activities of ‘overlapping small groups"