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Total Productive Maintenance

The Importance of Total Product Maintenance (TPM)

What is TPM?

Total Productive Maintenance or TPM is a system designed to stabilize equipment performance and reliability. It combines of three different types of maintenance including: autonomous maintenance, preventive maintenance, and early equipment maintenance. The primary goals of TPM are to eliminate waste caused by accidents, emergency and unscheduled downtime, defects, and speed loses.

Lean Maintenance Book 
 

Preventive Maintenance Made Visual

Discover the benefits of moving from reactive maintenance to predictive maintenance.

This e-book will explain the cost savings, improving safety, simplifying preventative maintenance, and much more.

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Total Productive Maintenance Examples and Visuals

Lubrication Visuals

Lubrication errors (both under and over lubrication) are one of the major causes of equipment failures. To maximize OEE, ensure employees can easily find lube point, readily detect the proper levels, and correctly apply the right amount of lubricant at the appropriate time.

Lubrication Visuals

Inspection Visuals

Total productive maintenance visuals make it easy for operators or anyone in the plant to quickly detect operating abnormalities and emerging failures before they happen.

Inspection Visuals

Speed Troubleshooting & Repair

Include "to" and "from" information on equipment ID labels to make it easier to trace lines in electrical and piping systems.

Speed Troubleshooting

Storeroom Management

Up to 25% of downtime is taken up with parts-related issues: going to get parts, looking for the right part, ordering parts, etc. Visuals can greatly simplify these tasks, resulting in faster turnaround, lower inventory costs and improved overall equipment effectiveness.

Storeroom Management

Predictive Maintenance

Use visuals to ensure that vibration, ultrasound and infrared measurements are taken at the exact same spot each time - no matter who takes the reading – to ensure comparable data over time.

Predictive Maintenance

Benefits of TPM and Preventive Maintenance

Moving from reactive to predictive maintenance

Many companies engage in reactive maintenance, which is when you wait for a problem to show up, and then fix it. But this method can be very expensive as it results in unplanned downtime. Innovators are now saving millions by using predictive analytics and maintenance techniques to anticipate problems before they occur.

 

TPM Predictive Maintenance

Direct Benefits of TPM

  • Can increase productivity and OPE (Overall Plant Efficiency) by 1.5 or 2 times
  • Reduce customer complaints
  • Can reduce the manufacturing cost by 30%
  • Can satisfy the customers needs by 100% (Delivering the right quantity at the right time, in the required quality)
  • Can reduce accidents

Indirect Benefits of TPM

  • Can increase confidence level among the employees
  • Helps keep the work place clean, neat and attractive
  • Can see a favorable change in the attitude of the operators
  • Helps achieve goals by working as a team
  • Horizontal deployment of new concepts in all areas of the organization
  • Share knowledge and experience
  • The workers can get a feeling of owning the machine
  • Follow pollution control measures

Product Recommendations

Here are our top product recommendations to get you started.

Resources

5S

5S and Lean

Learn more about one of the most widely adopted techniques from the lean manufacturing toolbox.

Learn More
Visual Workplace

Lean Visual Workplace

Learn more about one of the visual workplace in a lean manufacturing process.

Learn More
Preventative Maintenance Made Visual Image

Preventive Maintenance Made Visual

Discover the benefits of moving from reactive maintenance to predictive maintenance.

Download Now
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