Lean Manufacturing Techniques - Total Productive Maintenance

Total Productive Maintenance (TPM) is a well-established set of principles for optimising the effectiveness of manufacturing plant and equipment. It is team-based and involves every level and function in the organisation. The goal of a TPM programme is to markedly increase production, employee morale and job satisfaction.

TPM targets zero downtime of machinery/equipment, zero defects and zero accidents by the pro-active identification of potential problems, including:

  • preventive maintenance
  • corrective maintenance (improving equipment to prevent breakdowns or to make maintenance easier)
  • maintenance prevention (designing and installing equipment that needs little or no maintenance)
  • breakdown maintenance

TPM addresses the entire production environment and aims to build up a stable, shop floor-based system to prevent losses.

TPM Pillars

Introduction of a TPM programme is based on the implementation of a series of steps or Pillars:

  • Pillar 1 (5S) is a preparatory phase of TPM, which prepares the work place and the working environment and is a useful prelude to the TPM programme
  • Pillar 2 (Autonomous Maintenance) is aimed at developing machine operators to become responsible for the upkeep of their equipment, taking care of routine maintenance tasks, and elimination of production defects at source
  • Pillar 3 (Kaizen) is directed at introducing a number of small improvements, which should be carried out on a continual basis, to improve overall plant effectiveness
  • Pillar 4 (Planned Maintenance) is aimed at producing defect free products from efficient plant and equipment. This breaks maintenance down into the four groups, as defined above
  • Pillar 5 (Quality Maintenance) is focused on eliminating non-conformance in a systematic manner, using techniques such as prevention of defects at source, mistake-proofing and effective introduction of operator quality assurance
  • Pillar 6 (Training) is directed at creating a multi-skilled empowered workforce and is achieved by introducing a comprehensive programme for training and development
  • Pillar 7 (Office TPM) is intended to involve all people in company support functions to focus on better plant performance. The programme is aimed at bringing office activities up to the same level of efficiency as the shop floor
  • Pillar 8 (Safety) Safety is a cornerstone of TPM. The basic principle behind TPM safety activities is to address workplace organisation and discipline, regular inspections and servicing, and standardisation of work procedures