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Friday, December 19, 2008

Total Productive Maintenance (TPM)

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(Refer our High Quality Management Encyclopedia “Management Universe” at:

Journey of Maintenance Management
  • Total operations orientation: Attend to machines mainly when they breakdown (Breakdown maintenance=BM)
  • Cost optimization: Preventive maintenance (PM) in addition to breakdown maintenance optimally balanced to give cost minimization (Profitable preventive maintenance PPM=BM+PM)
  • System Orientation: Improve maintainability of machines in design and manufacture of machines such that no maintenance is needed; it is called maintenance prevention (MP). If at all maintenance is required rarely, maintainability should be high. We can call it maintainability improvement (MI) (Productive maintenance=BM+PM+MI+MP)
  • Company wide Involvement: Autonomous maintenance by operators, small group activities or quality circles by all the rest of the departments thus creating a company wide involvement (CI) (Total productive maintenance, TPM=BM+PM+MI+MP+CI)
Four Maintenance Models

  • Corrective Maintenance: Breakdown maintenance, defect analysis and corrective actions.
  • Preventive Maintenance: Periodic inspection and replacement and proper servicing at periodic intervals.
  • Predictive Maintenance: Predict future failure beforehand and carry out appropriate preventive measures, without shutting the plant, avoiding loss of production and prevention of stocking of spares for long times. This leads to maintainability improvement and maintenance prevention.
  • Total Productive Maintenance: Develop a system which is maintenance free using principles of preventive and predictive maintenance supported by company wide involvement.

Therefore, What is TPM?

  • To set a goal to maximize equipment efficiency (overall efficiency).
  • By establishing a total system for TPM for the entire life of equipment.
  • Participation by all departments at all levels, including equipment planning, operating and maintenance departments.
  • Involving/motivating all personnel including top personnel to first-line operators.
  • For promoting TPM by motivation management, namely, by autonomous small-group activities/voluntary activities.

Chronic Loss Solution Approach

  • Causes are unknown
  • Just address the cause
  • Use the why why or 5 why technique to go to the root cause level
  • Theoretically trace root of the cause
  • Solve at the root cause level
  • Even if not solved, clue to the solution is found

Desirable Actions and Aims of TPM

  • Aim at zero breakdown
  • MTBF (mean time between failures should be minimized)
  • MTRR (mean time to repair) should be brought down by breakdown maintenance efficiency
  • Preventive maintenance should be planned and implemented
  • Predictive maintenance should be planned and implemented
  • Warranty of maintenance concept should be implemented

For More Guidance, Assistance, Training and Consultation


Also refer: (Prodcons Group)
(Training Programs by Prodcons Group)
(Productivity Consultants)

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