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Total Productive Maintenance Tutorial | Get an Overview

Last updated on 24th Aug 2022, Blog, Tutorials

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Harsh Prakash (Education & Development Manager )

Harsh Prakash has more than five years of experience in autonomous maintenance, process and machine improvement, preventative maintenance, early management of new equipment, and process quality management.

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Introduction of Objectives of TPM:

In the Nineteen Fifties, Japanese national Seichi Nakajima developed a framework for the producing business and named it “Total Productive Maintenance” (TPM), that aims to scale back production and in operation prices by eliminating waste. Nakajima’s TPM model didn’t gain a lot of traction outside of Japan till it had been introduced by transnational car manufacturer Toyota within the Nineteen Seventies. famous worldwide because the father of TPM, Nakajima has enabled Toyota to require its performance to a subsequent level. Toyota’s implementation of Total Productive Maintenance expedited larger participation and engagement, enabled continuous improvement, and inspired staff to leverage their experience and data to boost OEE (Overall instrumentality Effectiveness). The subsequent article presents a comprehensive summary of total productive maintenance, the advantages of total productive maintenance, the 5s foundation of TPM, and its eight pillars.

total productive maintenance

What Is Total Productive Maintenance?

A key element of Lean Management/Manufacturing, Total Productive Maintenance embraces a comprehensive strategy to optimize facility maintenance with the first goal of eliminating resource waste, worker accidents, product defects and unplanned periods. These objectives are unit achieved through preventive maintenance, continuous coaching, and effective collaboration between production and maintenance personnel. With instrumentality effectiveness at its core, Total Productive Maintenance empowers instrumentality operators with talent coaching, proactive maintenance programs and productivity benchmark assessments, to require full charge of the upkeep of the assets appointed to them. The high degree of autonomy of the manpower reduces breakdown/over-reliance on responsive maintenance. a previous understanding of latest machines operational not solely helps attain optimized performance levels, however it additionally simplifies maintenance tasks dramatically.

Quality maintenance- the first objective of quality maintenance is to extend the standard of production by eliminating the underlying causes of failures and defects. It focuses on creating fault identification as an integral part of the production method.

Training and education- one amongst the most goals of total productive maintenance is to supply continuous and adequate coaching to deal with the talent gap of all personnel. This ensures that the complete work force, be it production managers, machine operators or maintenance technicians, remains extremely trained to satisfy TPM standards.

TPM in the workplace environment- TPM isn’t restricted to production facilities – it additionally aims to boost workplace and body functions. firms ought to bear in mind that principles of total productive maintenance ought to be adopted throughout the organizational structure, together with offices, which is able to facilitate waste elimination and increase body potency in procurance, order process and programming.

That (safety, health, environment- the highest priority of Total Productive Maintenance is to supply a healthy and safe system for all workers. Planned maintenance activities eliminate the danger of accidents, making certain accident free work surroundings.

What Is the Association Between TPM and OEE?

  • OEE (Overall instrumentation Effectiveness) may be a metric that scores the general effectiveness or health of apparatus, as a share, supporting its output quality, convenience and performance.
  • The OEE represents the Key Performance Indicator (KPI) of a complete productive maintenance program. It supports TPM methods by accurately following and achieving “Perfect Production” – optimized operation, no period of time, no defects.
  • Develop associate in-depth understanding of the Six alphabetic character phases of outline, Measure, Analyze, Improve and management (DMAIC) with Lean Six alphabetic character inexperienced Belt certification.

How are Six alphabetic characters and Lean Management associated with TPM?

Forward-thinking firms {increasingly|progressively|more associated more} take an approach to integrate total productive maintenance with Lean Management and 6 alphabetic character methodologies to extend production potency, scale back period of time, eliminate waste and supply bigger price to their customers. are adopting. Therefore, so as to completely implement the key principles of TPM, it’s necessary to grasp the overlapping ideas of Six alphabetic character and Lean Management practices.

With leading Six alphabetic character certifications like the IASSC and ASQ, Simpilern’s Lean Six alphabetic character inexperienced Belt coaching Course is one among the simplest industry-recognized courses obtainable on the market these days. giving fifty six hours of sensible learning, 33 PDUs, four real-world comes and four simulation papers, this course can give professionals the flexibility to strategize solutions, determine method problems and live performance, all of which are necessary in organizational development. accelerate.

Benefits of machine-controlled OEE Tracking:

Calculating OEE manually could be a good way to start out. This will be done with pencil and paper or with an easy computer programme, and needs only 5 items of knowledge (Schemed Production Time, Stop Time, Ideal Cycle Time, Total Count and Well Count). Playacting manual OEE calculations helps to bolster the underlying ideas and provides a deeper understanding of OEE. However, moving quick to machine-controlled OEE information assortment additionally has terribly sturdy benefits:

  • Stop time The accuracy of manual unplanned stop time pursuit is sometimes within the range of sixty to eightieth (based on real-world expertise in several companies). With automatic run/down detection, this accuracy will reach up to 100%.
  • Short Stops and Slow Cycles it’s not possible for many instrumentation to manually track slow cycles and short stops. This implies that an excellent deal of doubtless helpful data, like time-based and event-based loss patterns, isn’t accessible.
  • Operator focus it’s not possible for many instruments to manually track slow cycles and short stops. This implies that an excellent deal of doubtless helpful data, like time-based and event-based loss patterns, isn’t accessible.
  • Real-time results machine-controlled information assortment provides leads to real time, facultative correction techniques like assail (Short Interval Control).

Understanding the Six huge Losses:

six huge losses
  • The OEE loss classes (availability loss, performance loss, and quality loss) may be divided into what area unit ordinarily spoken because of the huge Six losses – the foremost common reason for lost productivity in producing. The six major disadvantages are very necessary as a result of they’re nearly universal in application to separate production, and that they offer an excellent beginning framework for considering, distinctive and assaultive waste (i.e. productivity loss).
  • Unplanned Stop handiness Loss Tooling failure, unplanned maintenance, bearing warming, motor failure Flexibility to line the vary between hit or miss stop (availability loss) and a shortstop (performance loss).
  • Setup and Adjustment handiness Loss setup/change, material shortage, operator shortage, major adjustment, prolusion time This disadvantage is commonly addressed through setup time reduction programs like SMED (Single-Minute Exchange of Die) Is.
  • Small Stop Performance Loss element Jam, Minor Adjustment, device Blocked, Delivery Blocked, Cleaning/Checking sometimes solely includes stops that area unit but 5 minutes long and don’t need maintenance personnel.
  • Slow running performance loss Incorrect setting, tool wear, alignment drawback something that forestalls instrumentation from running at its theoretical most speed.
  • Production defects Quality loss scrap, reject merchandising throughout steady-state production. Low Yield Quality Loss Scrap, Resale.


In the past, USA industries were reluctant to implement total productive maintenance in their current processes. In fact, a survey conducted by the Produce Analysis Centre showed that solely twenty seven % of respondents said that TPM was an Associate in Nursing existing business initiative, however only six % said they were totally implementing it. In addition, solely five % of respondents said that TPM was their plant’s approach to maintenance and reliability. Despite this lack of interest, plants around the world area unit reaping important edges from creating total productive maintenance the main target of their maintenance efforts. A study printed within the International Journal of Innovative Science, Engineering and Technology found that, in a very small-scale chemical compound company, the OEE worth before TPM implementation was seventy five %. when a TPM program was enforced, OEE improved to eighty five %, and a higher quality rate was achieved. The study disclosed that profitableness increased by twelve %, as breakdown and maintenance prices declined sharply (80 and twenty percent) whereas labor potency increased . several different tangible and intangible edges additionally emerged as a result of implementing the TPM programme.

One of the foremost mentioned case studies for TPM implementation is that of the Spanish American production company Cerveseria Cuoutémoc Moctezuma, the creator of six brands as well as Tecate, Dos Equis and Sol. This text details the company’s TPM success, showing however total productive maintenance works in a very real-world situation.

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