Full form of TPM (Total Productive Maintenance)

The full form of TPM is Total productive maintenance which is a concept used to increase overall equipment efficiency (OEE) as well as the capabilities and skills of plant personnel. It is built on eight pillars that support the concept and fulfil three objectives. TPM’s governing organisation is the Japan Institute of Plan Maintenance (JIPM). This article examines the beliefs and equipment associated with TPM in depth.

Introduction

The full form of TPM is Total productive maintenance

Total productive maintenance (TPM), which promotes a sense of ownership and accountability, is a proactive strategy that organizations work to implement to optimize operations, achieve maximum productivity, and cut costs. Employees at all levels may ensure the smooth operation of equipment and save downtime by actively participating in equipment maintenance.

The fundamental goals of TPM are to increase overall equipment effectiveness (OEE) and reduce failures, faults, and accidents. It promotes shared accountability, teamwork, and ongoing learning by including management, operators, and maintenance staff in developing a continuous improvement culture.

TPM models typically include a foundation known as 5S, which consists of Sort, Set in Order, Shine, Standardise, and Sustain. Additionally, the eight pillars provide support for traditional TPM models.

The 5S Foundation is built upon an arrangement of text and the sporadic removal of words, creating a unique conveyance of the same information. Do not always word things most logically; instead, utilize words that are not too uncommon to avoid sounding odd. Establishing a well-organized work environment is what 5S aims to achieve. Consisting of five elements, it ensures cleanliness and order.

We are discussing Full form of TPM (Total Productive Maintenance):

Here are the elements of the 5s foundation

1. Sort: remove everything that is not needed in the workspace
2. Straighten: organize the remaining objects.
3. Shine: clean and check the work environment
4. Standardise: create standards for performing the above three activities
5. Maintain: Ensure that the standards are followed regularly.

The full form of TPM is Total productive maintenance

The JIPM(Japan Institute of Plant Maintenance ) definition of TPM is as follows

• T stands for total. All personnel at all levels of the organization must be involved.
• P stands for productive. All resources are utilized effectively.
• M stands for maintenance. Keeping the Man-Machine-Material system in top shape.

JIPM created an eight-pillar TPM strategy to achieve firstly fewer Accidents, limited Breakdowns, and no Defects

The eight pillars of the JIPM model of TPM strategy are as follows;

• Focused Improvement
• Planned Maintenance
• Autonomous Maintenance
• Quality Maintenance
• Training and Education
• Office TPM
• Early Management
• Safety, Health, and Environment

TPM Components

TPM Pillars	Description
Autonomous	Operators take responsibility for daily maintenance, inspections, and minor repairs.
Maintenance	Ensure equipment operates within the desired quality parameters and minimises defects.
Planned Maintenance	Maintenance activities scheduled based on equipment conditions and prioritised by criticality.
Focused Improvement	Employees participate in problem-solving and improvement activities to eliminate losses and inefficiencies.
Early Equipment Management	Identifying potential issues and mitigating risks during the equipment’s design and installation phases.
Quality Maintenance	Ensuring equipment operates within the desired quality parameters and minimising defects.
Training	Training employees to enhance their skills, knowledge, and understanding of TPM principles.
Safety and Health	Integrating safety protocols and practices to eliminate accidents and create a safe working environment.

Focused improvement pillar

• The first pillar of TPM is focused improvement. It is said to provide a structured and team-based approach to eliminating specific identified losses in any process.
• The pillar follows the PDCA cycle, which is implemented to improve activities of any complexity in an organization. The PDCA cycle is defined as plan, do, check, and act.
• The pillar operates strategically and helps build an understanding and analysis of the different losses or threats affecting an organization. Identifying the criteria for project selection and TPM deployment that will deliver the business objectives
• The pillar helps teams become self-sufficient by using suitable problem-solving methodologies. The pillar guarantees that the staff has the skills and incentive to reduce losses from their processes, not just for chosen projects but also for everyday difficulties, by establishing competencies and embedding behaviors.
• The main advantages of the Pillar: The Focused Improvement Pillar guarantees that the strategy used is consistent and repeatable to ensure sustainability, boost efficiency, decrease defects, and enhance safety performance through loss elimination.

Autonomous Maintenance pillar

• TPM’s most important pillar is autonomous maintenance, which aims to improve personnel’s ability to comprehend, manage, and improve equipment and processes.
• The objective is to transition operators from a reactive to a proactive mindset, attaining optimal conditions and decreasing equipment pauses, faults, and failures.
• The installation of the Autonomous Maintenance pillar is divided into three phases, directed by the team that uses the equipment daily.
• In the first phase, fundamental equipment conditions are created and maintained by restoring and removing sources of forced degradation and contamination. Standards for cleaning, inspection, tightening, and lubrication are introduced.
• The second phase focuses on boosting the team’s capabilities by offering training on the detailed working principles of the equipment and improving the basic standard condition.
• During the third phase, operators assume entire control of the equipment as self-directed teams, constantly enhancing its condition and performance to minimize losses even more.
• Implementing the Autonomous Maintenance pillar improves Overall Equipment Effectiveness (OEE) by lowering performance loss and boosting equipment availability.
• As a result of deploying Autonomous Maintenance, employee engagement, and competency levels have seen demonstrable gains.

Planned maintenance pillar

• TPM’s primary pillar is planned maintenance, which attempts to achieve zero breakdowns by developing an organized management system.
• The maintenance team generally leads the operations under the Planned Maintenance pillar.
• To define the emphasis for improvement, the first phase of Planned Maintenance entails prioritizing equipment and reviewing existing maintenance performance and costs.
• The Autonomous Maintenance pillar assists in establishing a sustainable standard basic condition, and the team concentrates on identifying and reducing the causes of breakdowns.
• Information management systems collect thorough data on the maintenance process and the utilization of spare parts.
• The team evaluates the most effective method of equipment maintenance, beginning with a Periodic Maintenance (Time-Based Maintenance) system and progressing to Predictive Maintenance (Condition-Based Maintenance) systems when suitable and cost-efficient.
• The need for continuous improvement in the Planned Maintenance process is emphasized to eliminate reactive tasks and ensure equipment dependability.
• The key advantage of adopting Planned Maintenance is that breakdowns are reduced, resulting in decreased costs and greater machine efficiency.
• Implementing Planned Maintenance also helps the organisation enhance its quality and safety performance.
• To collect thorough data on the maintenance process and the utilisation of spare parts, information management systems are used.

Training and Education Pillar

The full form of TPM is Total productive maintenance

• Training and education is an important pillar of TPM, concentrating on the development of employee skills and knowledge required for effective TPM implementation and fulfilment of organisational goals.
• The first stage in Training and Education is to identify the knowledge and abilities needed for each profession, considering the complexity of the work and the number of skilled personnel required to serve the organization’s demands.
• A current status study compares existing skill levels to the set standards. Based on the study, a training plan is created to fill any discovered gaps.
• The execution of the training plan is closely monitored and assessed to ensure that it effectively improves the workforce’s targeted competencies and overall competence.
• The Training and Education pillar also includes creating, implementing, and refining a ‘Skill growth System’ that allows for continual staff growth.
• The Training and Education pillar increases as the TPM program continues to encompass more positions within the organization and solve increasingly sophisticated training demands.

Early Management pillar

• The fifth pillar of TPM is Early Management, which focuses on introducing new goods and processes with a reduced development lead time and vertical ramp-up.
• It is usually implemented after the first four pillars of TPM since it combines the learning and improvements gleaned from previous pillar teams.
• There are two elements to early management: early equipment and product management.
• From the commissioning stage onwards, Early Equipment Management strives to implement a loss-free and defect-free process, minimizing equipment downtime and optimizing maintenance costs.
• Early Product Management aims to reduce development lead times by allowing teams to engage on concurrent operations, eventually reaching vertical start-up with no quality loss or faults.
• Organizations may ensure the efficient and successful introduction of new goods and processes by applying Early Management practices, decreasing downtime, and optimizing quality and costs.

Quality Maintenance pillar

• The sixth pillar of TPM is Quality Maintenance, which focuses on achieving zero defect conditions by regulating process interactions.
• It seeks to avoid faults rather than depending on inspection techniques to find them afterward.
• After the first four pillars of TPM have been fully integrated, Quality Maintenance is deployed.
• Certain requirements must be addressed for effective adoption, such as eliminating forced degradation and resolving process issues.
• The first stage of Quality Maintenance entails defect analysis, identifying optimal circumstances, and implementing changes.
• The second phase focuses on quality maintenance by standardizing characteristics and processes to create a zero-defect system.
• Implementing quality maintenance may decrease the cost of poor quality, such as waste, rework, and customer complaints.
• Defects are seen as system failures, not the operator, and everyone takes responsibility for maintaining optimal conditions and striving for zero defects.

Office TPM pillar

The full form of TPM is Total productive maintenance

• TPM in the office focuses on administrative and support roles inside a company.
• The pillar employs TPM concepts to decrease waste and losses in these departments.
• The objective is to guarantee that office procedures help to optimize production processes at the lowest possible cost.
• The first step of preparation connects department aims and objectives with the vision and purpose of the organization.
• Within a certain duration, the Office TPM pillar performs five critical actions.
• Implementing versions of the Focused Improvement, Autonomous Maintenance, and Training and Education pillars are among these initiatives.
• The team also employs a flexible personnel approach to manage peak workloads without overstaffing.
• Through loss analysis, a prioritized improvement program aligns with the aims and objectives established during the preparatory activities phase.

Safety, Health, and Environment Pillar

• Within the TPM framework, the SHE pillar focuses on safety, health, and the environment.
• It strives for zero accidents, zero overburdening, and zero pollution.
• SHE techniques are implemented throughout the TPM deployment process.
• Activities include root cause analysis, reoccurrence avoidance, and proactive hazard reduction.
• The targets are people’s behaviors, machine conditions, and the management system.
• It is critical to align with external quality standards and certifications.
• The advantages include accident prevention, reduced small occurrences, the avoidance of environmental system failure, and a positive influence on the organization’s reputation.
• Cost minimization, inquiry, and compensation all result in financial savings.

Benefits of TPM

Employing a TPM has several advantages for organizations.

Key advantages include:

1. Increased device availability: Through proactive and autonomous maintenance, TPMs increase availability and save downtime by preventing device failures.

2. Enhanced Overall Equipment Efficiency (OEE): A TPM increases OEE by enhancing equipment functionality, reducing downtime, and minimizing mistakes and failures.

3. Lower costs: By emphasizing preventative maintenance, TPM lowers the cost of costly failures, urgent repairs, and lost productivity. Additionally, it increases equipment longevity and maximizes maintenance resources.

4. Enhanced employee participation: TPMs promote a culture of engagement and cooperation, enabling staff members to freely participate in maintenance tasks and continuous improvement initiatives.

The full form of TPM is Total productive maintenance.

5. Boost output and effectiveness: TPMs boost output and effectiveness by lowering waste, enhancing equipment dependability, and simplifying procedures.

FAQ’s

What are some common challenges in Total productive maintenance implementation?

Some common challenges in Total productive maintenance implementation include resistance to change, lack of employee buy-in and involvement, insufficient training and education, resource constraints, difficulty sustaining momentum, and difficulty measuring Total productive maintenance initiatives’ effectiveness. Overcoming these challenges requires strong leadership commitment, effective communication, and a systematic approach to implementation.

What is Autonomous Maintenance (AM) in TPM?

Autonomous Maintenance (AM) involves empowering operators and frontline employees to take responsibility for routine care, inspection, and minor maintenance of equipment. Through daily cleaning, lubrication, and inspection tasks, it aims to prevent equipment deterioration and breakdowns.

How does TPM differ from traditional maintenance approaches?

Unlike traditional reactive or preventive maintenance approaches, TPM emphasizes a proactive, holistic approach to equipment care. It involves all employees in maintenance activities, focuses on preventing losses and defects, and promotes a culture of continuous improvement and ownership.

Conclusion

Total Productive Maintenance (TPM) is a comprehensive strategy that promotes shared accountability, preventative maintenance, and continuous improvement. By incorporating all levels of the organization, TPM maximizes equipment availability, boosts productivity, and lowers costs. Implementation calls for dedication, training, and a methodical approach to guarantee that TPM’s guiding principles are successfully incorporated. By adopting TPM, organizations may realize their full potential and experience sustained growth in today’s cutthroat business climate.