Total Productive Maintenance (TPM) System

Overview

TPM originated in Japan in 1950 and was designed to support Total Quality Management. A research group was formed which later became the Japanese Institute of Plant Management (JIPM) with its initial focus on preventive maintenance. In 1960, TPM began focusing more on productive maintenance recognizing the importance of reliability, maintenance and economic efficiency in plant design.

TPM emphasizes proactive and preventative maintenance to maximize the operational efficiency of equipment. It blurs the distinction between the roles of production and maintenance by placing a strong emphasis on empowering operators to help maintain their equipment.

If companies want to achieve the full benefits of Lean Manufacturing, then TPM is crucial in optimizing the organization’s manpower, machinery and space utilization which in turn improves overall productivity.

The implementation of a TPM program creates a shared responsibility for equipment that encourages greater involvement by plant floor workers.

Outcomes

Successful deployment of TPM has the following expected outcomes:

• Improved equipment effectiveness
• Reduced machinery breakdowns
• Reduced costs related to equipment failure
• Improved maintenance efficiency and effectiveness
• Improved skills of all workers in manufacturing processes while involving them in routine maintenance
• Eliminated disruptions to the product path throughout the value chain flow

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