TPM Implementation

What is TPM Implementation?

The Term TPM is an abbreviation of the word Total Productive Maintenance. Total Productive Maintenance is originated from the Japanese industrial sector. The main objective of the TPM is to maintain & improve production systems. TPM focuses on creating a system in which that everyone in the facility is responsible for the maintenance rather than just the maintenance team.

TPM emphasizes the proactive & preventative maintenance of the machines & types of equipment in order to maximize the operational efficiency of the machines &  types of equipment. TPM works in order to prevent the problems from occurring, rather than responding to the problems.

In TPM, the workers are provided with training in order to maintain the types of equipment they work with & to look out for ways to improve the Overall Equipment Efficiency (OOE) which is determined by considering equipment’s availability, production & quality.

VIDEO : TPM Implementation


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Frequently Asked Questions (FAQ)

  • Initial visit & project kick-off meeting.
  • The initial visit of the plant.
  • Announce TPM Implementation Plan to the entire organization by top management.
  • Identification of the Pilot area for TPM.
  • Formation of the cross-functional team.
  • Returning the equipment’s to prime working condition.
  • Measurement of the Overall Equipment Efficiency (OEE).
  • Reviewing the major losses causes.
  • Initiating the proactive/ planned maintenance.
  • Implementing the TPM throughout entire organization.
  • Continuous review of OEE & actions to improve.
  • The Total Productive Maintenance (TPM) is based on the 5S foundation with 8 supporting activities known as pillars of the TPM. The pillars of TPM are as follows:
    • Autonomous Maintenance.
    • Focused Improvements.
    • Planned Maintenance.
    • Quality Maintenance.
    • Early Equipment Management.
    • Training & education.
    • Safety, Health & Environment.
    • TPM in administration.
  • This essential TPM component focuses on teaching and empowering maintenance employees, such as machine operators, to execute routine maintenance management on their own.
  • This TPM pillar relates to proactive maintenance procedures, which include assessing a current process holistically and suggesting ways to enhance it.
  • A scheduled maintenance programme uses past downtime data and predictive analytics to schedule important maintenance jobs around expected failure rates or idle times.
  • The quality maintenance process is intended to ensure that the actual maintenance operations done achieve the overall goals of error detection, defect prevention, and quality assurance.
  • Early equipment management ensures that the design of new pieces of equipment optimises the machinery’s lifespan, accessibility, and productivity by leveraging feedback from operators with practical experience. It is usually practiced when a new machine or equipment is procured.
  • The training & education related to TPM is provided on regular basis to fill the knowledge gaps necessary for achieving the TPM objectives. It is provided to the operators, workers, maintenance personnel & managers, etc.
  • The TPM emphasizes on the consideration of the health & safety of the employees while producing an environment that makes production more efficient. By creating safe workplace, the attitude of the employees tends to get better, since they don’t have to think about significant aspect. There by increasing productivity in significant manner.
  • Aside from purely mechanical factors, a well-designed TPM programme will search for methods to improve administrative tasks like as order processing and scheduling management in support of the production floor.
  • All organization irrespective of its shape & size where there is use of machines & equipment’s on daily basis.
  • Increase in productivity & overall plant efficiency.
  • Less quality-related customer complaints.
  • Less Manufacturing cost.
  • Less Machine downtime.
  • Accident reduced.
  • Employee Morale boost.
  • Neat & clean workplace.
  • Better energy saving.

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