Total Productive Maintenance (TPM) is a method of physical asset management focused on maintaining and improving manufacturing machinery, in order to reduce the operating cost to an organization.
TPM is designed to disseminate the responsibility for maintenance and machine performance, improving employee engagement and teamwork within management, engineering, maintenance, and operations.
The goal of TPM is the continuous improvement of equipment effectiveness through engaging those that impact on it in small group improvement activities. Total quality management (TQM) and total productive maintenance (TPM) are considered as the key operational activities of the quality management system. In order for TPM to be effective, the full support of the total workforce is required. This should result in accomplishing the goal of TPM: “Enhance the volume of the production, employee morals, and job satisfaction.”
The main objective of TPM is to increase the Overall Equipment Effectiveness (OEE) of plant equipment. TPM addresses the causes for accelerated deterioration while creating the correct environment between operators and equipment to create ownership.
OEE has three factors which are multiplied to give one measure called OEE
Performance x Availability x Quality = OEE
Each factor has two associated losses making 6 in total, these 6 losses are as follows:
Performance = (1) running at reduced speed – (2) Minor Stops
Availability = (3) Breakdowns – (4) Product changeover
Quality = (5) Startup rejects – (6) Running rejects
The objective finally is to identify then prioritize and eliminate the causes of the losses. This is done by self-managing teams that solve problems. Employing consultants to create this culture is a common practice.
The eight pillars of TPM are mostly focused on proactive and preventive techniques for improving equipment reliability:
- Autonomous Maintenance
- Focused Improvement
- Planned Maintenance
- Quality management
- Early/equipment management
- Education and Training
- Administrative & office TPM
- Safety Health Environmental condition’s
With the help of these pillars, we can increase productivity. Manufacturing support.
Following are the steps involved by the implementation of TPM in an organization:
- Initial evaluation of TPM level,
- Introductory Education and Propaganda (IEP) for TPM,
- Formation of TPM committee,
- Development of a master plan for TPM implementation,
- Stage by stage training to the employees and stakeholders on all eight pillars of TPM,
- The implementation preparation process,
- Establishing the TPM policies and goals and development of a road map for TPM implementation.