Full form of TPM (Total Productive Maintenance)

Last updated on July 22nd, 2023 at 12:52 pm

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 organisations work to implement in order to optimise 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 the development of 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, there are eight pillars that provide support in 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 in the most logical fashion; instead, utilise words that are not too uncommon, as to avoid sounding odd. Establishing a well-organised work environment is what 5S aims to achieve. Consisting of five elements, it ensures cleanliness and order.

Here are the elements of 5s foundation:

Sort: remove everything that is not actually needed in the work space

Straighten: organise the remaining objects

Shine: clean and check the work environment

Standardise: create standards for performing the above three activities

Maintain: Ensure that the standards are followed on a regular basis

The full form of TPM is Total productive maintenance

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

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

JIPM created an eight-pillar TPM strategy with the goal of achieving firstly with less Accidents ,limited Breakdowns and with no Defects

The eight pillars of 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	Preventive maintenance carried out by the operators to prevent deterioration and breakdowns.
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.

1-Focused improvement pillar

• The first pillar of TPM is focused improvement. It is said to provide a structured and team-based approach to eliminating any specific identified losses in any process.
• The pillar follows the PDCA cycle, which is implemented to improve activities of any complexity in an organisation. The PDCA cycle is defined as plan,do, check, and act.
• The pillar operates at a strategic level and helps build an understanding and analysis of the different losses or threats affecting an organisation. 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 competences and embedding behaviours.
• The main advantages of the Pillar: The Focused Improvement Pillar guarantees that the strategy used is consistent and repeatable to ensure sustainability, as well as boosting efficiency, decreasing defects, and enhancing safety performance through loss elimination.

2-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, which are directed by the team that uses the equipment on a daily basis.
• 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 minimise 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.

3-Planned maintenance pillar

• TPM’s primary pillar is planned maintenance, which attempts to achieve zero breakdowns by developing an organised 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 prioritising equipment and reviewing existing maintenance performance and costs.
• The Autonomous Maintenance pillar is given assistance in establishing a sustainable standard basic condition, and the team concentrates on identifying and reducing the causes of breakdowns.
• To collect thorough data on the maintenance process and the utilisation of spare parts, information management systems are used.
• The team evaluates the most effective method to 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 of continuous improvement in the Planned Maintenance process is emphasised, with the goal of eliminating reactive tasks and ensuring 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.

4- 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, taking into account the complexity of the work and the number of skilled personnel required to serve the organisation’s demands.
• A current status study is performed to compare existing skill levels to the set standards. Based on the study, a training plan is created to fill any gaps that are discovered.
• The training plan’s execution 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 the creation, implementation, and continued refinement of a ‘Skill growth System’ that allows for continual staff growth.
• The Training and Education pillar increases as the TPM programme continues to encompass more positions within the organisation and solve increasingly sophisticated training demands.

5- Early Management pillar

• The fifth pillar of TPM is Early Management, which focuses on the introduction of 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 management and early product management.
• From the commissioning stage onwards, Early Equipment Management strives to implement a loss-free and defect-free process, minimising equipment downtime and optimising maintenance costs.
• The purpose of Early Product Management is to reduce development lead times by allowing teams to engage on concurrent operations, eventually reaching vertical start-up with no quality loss or faults.
• Organisations may assure the efficient and successful introduction of new goods and processes by applying Early Management practises, decreasing downtime and optimising quality and costs.

6- 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 afterwards.
• After the first four pillars of TPM have been fully integrated, Quality Maintenance is deployed.
• For effective adoption, certain requirements must be addressed, 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 standardising characteristics and processes in order to create a zero-defect system.
• Organisations may decrease the cost of poor quality, such as waste, rework, and customer complaints, by implementing Quality Maintenance.
• Defects are seen as failures of the system, not the operator, and everyone takes responsibility for maintaining optimal conditions and striving for zero defects.

7-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.
• To decrease waste and losses in these departments, the pillar employs TPM concepts.
• The objective is to guarantee that office procedures help to optimise production processes at the lowest possible cost.
• The first step of preparation connects department aims and objectives with the vision and purpose of the organisation.
• 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.
• To manage peak workloads without overstaffing, the team also employs a flexible personnel approach.
• Through loss analysis, a prioritised improvement programme is created that aligns with the aims and objectives established during the preparatory activities phase.

8-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.
• People’s behaviours, machine conditions, and the management system are all targets.
• It is critical to align with external quality standards and certifications.
• The advantages include accident prevention, a reduction in small occurrences, and the avoidance of environmental system failure and Positive influence on the reputation of the organisation.
• Cost minimization, inquiry, and compensation all result in financial savings.

Benefits of TPM: 

Employing a TPM has several advantages for organisations. Key advantages include of:

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

2. Enhanced Overall Equipment Efficiency (OEE): A TPM increases OEE by enhancing equipment functionality, cutting down on downtime, and minimising mistakes and failures.

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

4. Enhanced employee participation: TPMs promote a culture of engagement and cooperation, enabling staff members to freely take part in upkeep 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.

Conclusion:

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