Empowering Lean Solutions for Everyone

Total Productive Maintenance

Definition of TPM

Total Productive Maintenance represents a set of techniques to ensure that every machine in a production process is always able to perform its required tasks (maximum machine availability.

A TPM Package is available if you require more information.

Goals

  • Zero accidents
  • Zero breakdowns
  • Zero defects
  • Zero loss of equipment speed

Benefits

  • Improves safety
  • Improves environment (zero leaks, spills)Improves quality
  • Employee involvement morale
  • Improves skill level of all employees
  • Building block for Lean Manufacturing
  • Cost reduction

Characteristics

  • It requires the participation of all employees (maintenance personnel, line managers, manufacturing engineers, quality personnel, and operators)Operators perform daily activities such as inspecting equipment, cleaning, lubricating, etc.
  • It focuses on the major 6 losses
    1. Equipment breakdowns – downtime
    2. Setup and minor adjustments (changeover)
    3. Idling and minor stoppages
    4. Reduced speed
    5. Scrap and rework
    6. It addresses the total life cycle of equipment to revise the maintenance practices, activities, and improvements in relation to where the equipment is in its life cycle

Major Components

  1. Autonomous Maintenance
    • It involves operators performing routine tasks focused on preventing early equipment deterioration, controlling contamination
  2. Predictive Maintenance Techniques
    • Oil analysis
    • Vibration analysis
    • Infrared analysis
    • Thermography
  3. Preventive Maintenance Techniques
    • Lubrication
    • Visual Inspection
    • Filter change
    • Oil change
    • Wear parts replacement
    • etc.