Lengthy delays occur and valuable resources are wasted when a machine or piece of equipment is always on the fritz, costing an organization big time. Total productive maintenance, or TPM, is a manufacturing concept that addresses this issue through preventive and predictive measures, integrating maintenance into daily activities, and instilling a sense of responsibility for equipment into employees. By taking a proactive approach to maintenance, you are far more likely to avoid problems like slow-running machines or constant breakdowns. TPM can also impact facility safety by reducing the number of accidents and injuries resulting from slow or faulty machines.
TPM was first developed at a Toyota Group company in the 1960s by Seiichi Nakajima and was originally intended to be used in the automotive industry. It was soon realized however, that this fairly straight-forward strategy can be easily translated across industries. The principles and tools behind total productive maintenance can be implemented in manufacturing facilities, offices, or even in healthcare.
The total productive maintenance system is made up of eight pillars - primary concepts focused on proactive techniques to improve equipment effectiveness and reliability, which in turn improves productivity. These eight pillars include concepts like planned maintenance, quality management, and focused improvement. TPM strategies and activities are most effective when there is full employee participation, meaning you will need to provide training and support for workers.
Because TPM is a Lean tool, it is often used alongside other Lean tools like Kaizen, OEE, or 5S. For instance, TPM is sometimes referred to as an extension of the 5S methodology and the pillars of TPM are built upon the 5S foundation. 5S works to reduce wastes that are a result of a cluttered, disorganized space while TPM aims to reduce wasted caused by equipment malfunctions and required maintenance. When the two are implemented jointly, they work together to eliminate all avoidable wastes.
- How is TPM and Lean related?
- What are the pillars of TPM?
- What are some tools of TPM?
- What is the difference between TPM and TQM?
- Who developed TPM?
- What are the steps to implementing TPM?