Total Productive Maintenance

What Is Total Productive Maintenance?
A system for designing or selecting, correcting, and maintaining equipment so that breakdowns rarely occur during production activities.

• The most efficient use of equipment


• A company-wide Preventive Maintenance system


• Includes all employees


• Autonomous maintenance driven

Types of Maintenance

• Maintenance Prevention - Designing/selecting equipment that will run with min. maintenance and easy to service


• Predictive Maintenance - Determining life expectancy of parts/components replacing them at the optimum times


• Corrective Maintenance - Improving performance of equipment or altering equipment for manufacturing needs


• Preventive Maintenance - Scheduling/planning maintenance activities for smooth operation of equipment


• Autonomous Maintenance - Involving production employees in all aspects of the machine maintenance process

Goals of Total Productive Maintenance

• Zero Unplanned Downtime


• Zero Defects


• Zero Speed Losses


• Zero Accidents


• A Long Healthy Machine Life Cycle With Minimum Repair Costs

Want to turn your maintenance from a repair function to a reliability function? Total Productive Maintenance (TPM) is the vehicle to do that! Total Productive Maintenance (TPM) concentrates on getting the productivity needed from your current equipment assets. “Needed” means high Overall Equipment Effectiveness (OEE) measured over the time you need that equipment to meet daily customer demand. In KAIZEN Lean, Overall Equipment Effectiveness (OEE) is measured over the actual customer demand time, not over the maximum scheduled production time a piece of equipment could run. This is an important distinction.
Total Productive Maintenance (TPM) can give you Overall Equipment Effectiveness (OEE) in the mid to upper 90% without major capital expenditures!

Total Productive Maintenance (TPM) enables participants to:

• Understand and describe the 6 major losses in equipment effectiveness


• Categorize maintenance in the 5 Total Productive Maintenance (TPM) “pillars”


• Measure Overall Equipment Effectiveness (OEE) on each piece of equipment in their Value Stream


• Improve Overall Equipment Effectiveness (OEE) via application of Total Productive Maintenance’s (TPM) 5 Pillars


• Know the differences between Reactive, Preventive, Predictive, and Proactive Maintenance


• Accomplish Actual TPM Implementation With Measurable Results

Total Productive Maintenance (TPM) 5 Day Hands-On Workshop

Day 1

• Total Productive Maintenance Introduction


• Lock-out Tag-out Review


• Begin Phase 1 Implementation (Shop Floor)

Day 2

• TPM Standards


• 5 Pillars of Total Productive Maintenance


• Visual controls

Begin Phase 2 Implementation (Shop Floor)

Day 3

• Understanding Equipment Losses


• Eliminating Equipment Losses


• Begin Phase 3 Implementation (Shop Floor)


• TPM Tools & Techniques Explained


• Gaining Access to the “Inaccessible”

Day 4

• Analysis & Instruction Standards


• OEE Overall Equipment Effectiveness


• Basic Equipment Knowledge


• Begin Phase 4 Implementation (Shop Floor)

Day 5

• Wrap-up Shop Floor Implementation


• Review TPM Fundamentals


• Advanced TPM Concepts


• Calculating Machine Capacity


• R.O.I. & Record Keeping


• TPM Team Presentations