Total Productive Maintenance (TPM) is a proactive approach to maintenance that focuses on maximizing the productivity of equipment by involving all employees in the maintenance process. It is a holistic approach that involves the entire organization, from front-line workers to management, in the pursuit of continuous improvement.
In the manufacturing industry, TPM has become an essential process that has added value to the production process by improving the reliability of the equipment, reducing downtime, and increasing productivity. The goal of TPM is to improve the overall equipment effectiveness (OEE), which is a measure of the equipment’s performance, availability, and quality.
There are two types of maintenance: reactive and proactive. Reactive maintenance is done after a problem has occurred, while proactive maintenance is done to prevent problems from occurring. TPM falls under proactive maintenance since it focuses on preventing equipment breakdowns and improving the overall performance of equipment.
TPM is based on the premise that everyone in the organization, from operators to managers, has a role to play in the maintenance of equipment. This approach shifts the responsibility of maintenance from solely the maintenance department to all employees in the organization. TPM encourages employees to take ownership of their equipment, and this creates a sense of ownership and pride in the workplace.
TPM consists of eight pillars:
1. Autonomous maintenance:
This involves operators taking ownership of their equipment by performing routine cleaning, lubrication, and inspections.
2. Planned maintenance:
This involves scheduling and planning maintenance activities to prevent breakdowns.
3. Quality maintenance:
This involves preventing defects from occurring by focusing on overall equipment effectiveness.
4. Training and development:
This involves providing employees with the necessary skills and training to perform maintenance tasks effectively.
5. Early equipment management:
This involves designing equipment that is easy to maintain and making improvements to existing equipment to reduce maintenance needs.
6. Health, safety, and environment:
This involves integrating health, safety, and environmental concerns into maintenance activities.
7. Office TPM:
This involves applying TPM principles to office processes to improve efficiency and productivity.
8. TPM in administration:
This involves applying TPM principles to administrative processes to improve efficiency and productivity.
When TPM is implemented effectively, it can lead to numerous benefits, including:
1. Increased productivity
2. Reduced downtime
3. Improved product quality
4. Increased equipment reliability
5. Reduced maintenance costs
6. Improved workplace morale
7. Reduced environmental impact
In conclusion, TPM is a proactive approach to maintenance that involves all employees in the maintenance process. It focuses on preventing equipment breakdowns and improving the overall performance of equipment. The eight pillars of TPM provide a comprehensive framework for implementing TPM effectively. When implemented effectively, TPM can lead to numerous benefits, including increased productivity, reduced downtime, improved product quality, increased equipment reliability, reduced maintenance costs, improved workplace morale, and reduced environmental impact.
