Total productive maintenance is a system of maintaining and improving the integrity of production, safety and quality systems through the machines, equipment, processes, and employees that add business value to an organization. Total Productive Maintenance (TPM) was developed by Seiichi Nakajima based on experience of the practical application of maintenance best practice in Japan between 1950 and 1970. This experience led to the recognition that a leadership mindset engaging front line teams in small group improvement activity is an essential element of effective operation. The outcome from his work was the application of the TPM process in 1971. One of the first companies to gain from this was Nippondenso, a company that created parts for Toyota.
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.
- Step one: Identify a pilot area. …
- Step two: Return equipment to its basic condition. …
- Step three: Measure OEE. …
- Step four: Reduce major losses. …
- Step five: Implement planned maintenance.
8 PILLARS OF TOTAL PRODUCTIVE MAINTENANCE (TPM)
1. Continuous Improvement
-Applied elimination of major losses
2. Automonous Maintenance
-Operator executes inspections, cleanings and maintenance independence independently.
3. Preventive Maintenance
-Undisturbed machines and facilities produce faulties goods for total customer satisfaction
4. Trainings and Education
-Tailored qualification of employees to improve their abilities to operate and maintain
5. Start-up Monitoring
-Realization of a vertical starting curve at new products and facilities
6. Quality Management
– ‘Zero defects’ target concerning products and facilities
– Customer satisfaction through highest quality and accurate manufactures
– Systematic elimination of facilities parts, which have negative impact on productivity
7. TPM in Administration
– Elimination of losses and waste in non-productive sections
8. Safety and Health at Work, Environment Protection
-Zero accidents, zero pollution, zero illnesses