What Is TPM? The 8 Core Pillars of Total Productive Maintenance
What is TPM (Total Productive Maintenance), what are its 8 core pillars and how does it relate to OEE? We explain the path to the zero-breakdown goal in production.
TPM, or Total Productive Maintenance, is a management approach that makes maintenance activities the responsibility of everyone from operator to manager, not just the maintenance team, in order to improve equipment performance. Developed by JIPM in Japan, the method spread worldwide through the work of Seiichi Nakajima.
What Is the Purpose of TPM?
The core goal of TPM is summarized as “three zeros”: zero unplanned stoppages, zero quality defects and zero accidents. To reach this goal, losses must be systematically eliminated throughout the life of the machine.
The 8 Core Pillars of TPM
The classic JIPM model consists of eight pillars: autonomous maintenance, planned maintenance, focused improvement (kobetsu kaizen), quality maintenance, early equipment management, education and training, safety-health-environment, and office TPM (TPM in administrative processes). Each pillar targets a different source of losses.
What Is Autonomous Maintenance?
It is the operator taking on the cleaning, lubrication and simple checks of their own machine. Cleaning is in fact an inspection; the operator is the person who notices abnormalities earliest. The foundation of autonomous maintenance is 5S discipline.
The Relationship Between TPM and OEE
The main performance indicator of TPM is OEE (Overall Equipment Effectiveness). OEE is calculated as the product of availability, performance and quality rates. The six big losses (breakdowns, setup and adjustment, minor stoppages, speed loss, process defects, start-up losses) are the main causes that lower OEE.
How Does TPM Implementation Start?
Selecting a pilot line, measuring current OEE, loss analysis, starting the autonomous maintenance steps and setting up a planned maintenance system are the typical starting steps. For sustainable results, top management ownership and regular follow-up on the floor are essential.
To set up a TPM system in your factory, you can explore our TPM consulting service or contact us..
