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A Comprehensive Guide to Total Productive Maintenance (TPM)

A Comprehensive Guide to Total Productive Maintenance (TPM)
June 18, 2024
Smart Audits
Lean Manufacturing

Total Productive Maintenance (TPM) is a methodical approach committed to improving the effectiveness and efficiency of equipment and machinery. It stresses the importance of proactive and preventive maintenance, aiming for an optimal production environment with zero accidents, zero defects, and zero breakdowns.

This approach requires the active involvement of all departments, from top-level management to frontline operators, to ensure the reliability and integrity of production and quality systems. The implementation of TPM can significantly enhance the overall equipment effectiveness (OEE) while minimizing downtime.

Understanding TPM

TPM is a holistic approach that emphasizes the importance of equipment maintenance through the active participation of all employees. The primary purpose is to achieve perfect production, characterized by:

  • No Breakdowns
  • No Small Stops or Slow Running
  • No Defects
  • No Accidents

The implementation of TPM involves the creation of a shared responsibility for equipment, encouraging greater involvement by plant floor workers. In the right environment, this can be very effective in improving productivity by increasing uptime, reducing cycle times, and eliminating defects.

Through TPM, the traditional approach of "we'll fix it when it breaks" is transformed into a proactive mindset that places machinery at the core focus of an operation and maximizes its availability.

How TPM enhances Overall Equipment Effectiveness (OEE)

A critical measure of TPM effectiveness is the Overall Equipment Effectiveness (OEE) score. OEE is a metric that identifies the percentage of planned production time that is genuinely productive. The goal is to improve OEE by reducing downtime through effective implementation of a TPM program.

OEE consists of three underlying components:

  • Availability: It takes into account any event that stops planned production for a significant length of time.

  • Performance: It includes all factors that cause production to operate at less than the maximum possible speed when running.

  • Quality: It factors out manufactured pieces that do not meet quality standards, including pieces that require rework.


Advantages of Total Productive Maintenance

The transition from reactive to predictive maintenance is one of the most significant benefits of implementing a TPM program. Here are some of the direct and indirect advantages of TPM:

Direct Benefits:

  • Reduction in unplanned downtime, leading to an increase in OEE.
  • Lower customer complaints.
  • Decrease in workplace accidents.
  • Reduction in manufacturing costs.
  • Improvement in product quality.

Indirect Benefits:

  • Increase in employee confidence levels.
  • Creation of a clean, well-organized workplace.
  • Rise in positive attitudes among employees through a sense of ownership.
  • Adherence to pollution control measures.

The 8 Pillars of Total Productive Maintenance

Traditional TPM is built on eight pillars based on the 5-S system. These eight pillars focus on proactive and preventive techniques to help improve equipment reliability.

  1. Autonomous Maintenance: Fosters a sense of ownership among operators by allowing them to maintain their equipment.

  2. Focused Improvement: Encourages small teams to work together to implement regular, incremental improvements to equipment operation.

  3. Planned Maintenance: Involves scheduling maintenance tasks based on predicted or measured failure rates.

  4. Quality Management: Works on design error detection and prevention into the production process.

  5. Early Equipment Management: Utilizes the knowledge gained through TPM to improve the design of new equipment.

  6. Training and Education: Addresses knowledge gaps to ensure TPM goals are achievable.

  7. Safety, Health, Environment: Maintains a safe and healthy working environment, eliminating potential health and safety risks.

  8. TPM in Administration: Looks beyond the plant floor by addressing and eliminating

Total Productive Maintenance (TPM) Img

Implementing TPM

Implementing TPM involves a five-step process:

  1. Identifying a Pilot Area: This involves selecting a specific piece of equipment or area for the pilot TPM program.

  2. Restoring Equipment to Prime Operating Condition: This involves using the 5S system and autonomous maintenance to clean up and prepare the equipment for improved operation.

  3. Measuring OEE: This involves setting up a system to track OEE for the target equipment.

  4. Addressing and Reducing Major Losses: This involves forming small, multidisciplinary teams to address core areas such as preventive and autonomous maintenance and the standardization of work processes.

  5. Implementing Planned Maintenance: This involves integrating proactive maintenance techniques into the TPM program.

While these steps cover the basic aspects of TPM, there are additional activities that can further enhance the effectiveness of the program. These include quality maintenance, early equipment management, safety, health, and environment, and TPM in administration. These activities should be integrated as needed based on the specific requirements of the organization.

Sustaining the Improvement Achieved with TPM

Achieving sustainable improvement is one of the greatest challenges in any company. Engaging employees, succeeding early, providing active leadership, and evolving the initiative are key to ensuring the long-term success of TPM initiatives.

Total Productive Maintenance and Mobile2b

In today’s digital landscape, platforms like Mobile2b are subtly reshaping how businesses implement Total Productive Maintenance (TPM). Developed in Germany, Mobile2b focuses on digitalizing and automating workflows, which helps streamline TPM integration into daily operations. This platform offers tools for effective real-time monitoring and management of maintenance activities, supporting the continuous oversight and optimization of equipment performance. By utilizing Mobile2b, businesses can enhance their maintenance strategies with greater ease and efficiency, ensuring that TPM objectives are met with consistency and precision.

Wrapping Up

In conclusion, Total Productive Maintenance is a pivotal strategy in the industrial manufacturing sector. With its focus on proactive and preventive maintenance, it not only ensures the optimal performance of equipment but also enhances the overall productivity of the business. Furthermore, with the integration of digital solutions like Mobile2b, TPM becomes even more manageable and effective.

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