Total Productive Maintenance (TPM)

Total Productive Maintenance (TPM) is a technique designed to optimise the utilisation, performance, and productivity of an organisations plant and equipment. This is achieved through the involvement of the entire workforce in the pursuit of common and appropriate objectives.

The overall objective is to establish a system where all stakeholders work together to help reduce breakdowns, restore or improve on original or intended efficiencies, and reduce and eventually eliminate quality defects.

This programme deals with the evolution of an organisation from Breakdown Maintenance through Preventative Maintenance and on to Total Productive Maintenance.

Total Productive Maintenance (TPM) is one of the integrated tools that is used in the pursuit of improving Overall Equipment Effectiveness (OEE); therefore an understanding of OEE will be an integral part of any TPM initiative.

Total Productive Maintenance (TPM) addresses the “Six Big Losses” associated with Plant and Equipment, which are:

Equipment Failure
Changeover – Set up and adjustments
Idling & Minor Stoppages
Reduced Speed
Process Defect
Reduced Yield

Interested parties should be any stakeholders involved with the performance of plant and equipment, which could include:

Production Engineering
Maintenance
Setters
Operators
Team Leaders
Middle Managers

Total Productive Maintenance (TPM) programme covers:

• Introduction to TPM, its aims, and why TPM is appropriate.
• Setting Goals, Targets and establishing a TPM strategy.
• Identification of Waste & Losses
• The calculation and monitoring of O.E.E.
• Small group, autonomous maintenance and focused improvement activities.
• Forced and natural deterioration.
• Contamination, the source and countermeasures.
• The five pillars of TPM.
• The integration with Changeover (S.M.E.D.) and Workplace Organisation (5S)

• Understand O.E.E. and how a properly conducted T.P.M. programme will have a positive impact on this measure and hence plant performance.
• Identify, Pareto, and monitor TPM Improvement Opportunities. Implement appropriate improvement actions.
• Participate in the development of an ongoing strategy for optimising the effectiveness of plant and machinery.
• Develop a sense of ownership of their equipment.

Total Productive Maintenance Case Study

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