Total Productive Maintenance (TPM) is a series of methods to ensure that every machine in a production process is always able to perform its required tasks through improved equipment availability / uptime. TPM is based on employee participation – teamwork skills and flexibility are improved between operators and maintenance personnel as operators perform planned maintenance and maintenance staff spend less time fire fighting . It identifies and eliminates the six big production losses (set-ups and adjustments, breakdowns, idling and minor stops, start-up / yield loss, defects and rework, and reduced running speed) of overall equipment effectiveness (OEE) through:
- preventive and predictive maintenance: Maintenance teams conduct daily and periodic maintenance and inspection, predictive maintenance (using technologies that determine “when” something is going to break), improvements to lengthen equipment life, spare parts control, breakdown analysis and lubrication control.
- maintenance prevention: Maintenance, design engineers and production engineers establish design goals; maintainability, operability and reliability of equipment; lower life cycle costing, and anticipate and prevent production problems during design and debug stages.
- autonomous maintenance: Operators are involved in maintaining their own equipment. They participate by conducting initial cleaning (5S), making cleaning and inspection easier, setting cleaning and lubrication standards, developing general inspection skills, and conducting daily cleaning and inspection.