Total Productive Maintenance (TPM) for Manufacturing
Total Productive Maintenance (TPM) is a holistic approach to equipment maintenance that aims for zero breakdowns, zero defects, and zero accidents by involving all employees.
The Eight Pillars of TPM
| Pillar | Focus | Key Actions |
|---|---|---|
| Autonomous maintenance | Operator daily care | Clean, inspect, lubricate, tighten. Training for basic adjustments. |
| Planned maintenance | Scheduled interventions | PM schedules, spare parts management, maintenance standards. |
| Focused improvement | Eliminate losses | Kaizen events, root cause analysis, OEE improvement projects. |
| Early equipment management | Design for maintainability | MP (Maintenance Prevention) design during equipment procurement. |
| Quality maintenance | Zero defect conditions | Detect abnormalities before they cause defects. Poka-yoke. |
| Training & development | Multi-skilled operators | Skills matrix, training plans, certification for maintenance tasks. |
| Office TPM | Administrative efficiency | 5S in office, reduced lead time, streamlined processes. |
| Safety, health & environment | Zero accidents | Risk assessments, LOTO procedures, ergonomic improvements. |
Six Major Losses
- Equipment failure / breakdown — Unplanned downtime
- Setup and adjustment — Changeover time, SMED target
- Idling and minor stops — Brief interruptions (<5 minutes)
- Reduced speed — Operating below design speed
- Process defects — Scrap and rework during production
- Reduced yield — Startup losses, warm-up scrap
OEE Calculation
OEE = Availability × Performance × Quality
- Availability: (Operating time / Planned production time). Target: >90%
- Performance: (Ideal cycle time × Total parts / Operating time). Target: >95%
- Quality: (Good parts / Total parts). Target: >99.9%
- World-class OEE: >85% (0.90 × 0.95 × 0.999 = 85.4%)
Implementation Roadmap
- Phase 1 (months 1-6): 5S foundation, autonomous maintenance on critical equipment, measure baseline OEE
- Phase 2 (months 6-18): Planned maintenance system, focused improvement projects, operator training
- Phase 3 (months 18-36): Quality maintenance, early equipment management, extend TPM to support areas
- Phase 4 (ongoing): Continuous improvement culture, TPM awards, supplier TPM integration