Total Productive Maintenance

« Productive Maintenance carried out by all employees through small group activities”   Seiichi Nakajima

This Proven Strategy for managing equipment was born in Japan after the Second World War. It only really started in the Toyota plants in Japan in the early 70s. The successes of this Global Approach to improve Productivity, Quality and safety of Workers have quickly made ​​it very popular. The application of these concepts quickly spread around the world and this evolutionary strategy is part of the  forefront of Best Practices.

Its Ultimate Goal is to maximize the performance of facilities, and the pursuit of minimum Life Cycle Cost (LCC) .

Eliminating waste due to incidents and deficiencies in facilities, Equipment becomes easier to operate and more reliable, maintenance is cheaper and then verification is facilitated by Visual Controls. The gradual transformation of the equipment, people and workplace forms the basis of the TPM.

With TPM, Operators take ownership of their Production Equipment.

TPM’s success is based on small multidisciplinary group activities and the close collaboration between the the operation, maintenance and engineering staff.

TPM generates impressive and lasting results

  • Increase the availability and efficiency of production equipment
  • Generates a better quality – “done right the first time”
  • Makes the working environment cleaner and safer
  • Causes a drastic drop in failures and unplanned stoppages
  • Substantially reduce costs:
    • Operation
    • Maintenance
    • Inventories
  • Equipments become:
    • Easier to operate
    • More reliable
  • Generate a sense of pride in his workplace

The Implementation of the TPM automatically implies:

  • acquiring a better knowledge of the Equipments
  • learning an effective cleaning method and order to better inspect and then:
  • ability to detect abnormalities to then make the appropriate adjustments and therefore:
  • Improving Performance. (the goal)

One of the 8 pillars of TPM is self-maintenance or Autonomous maintenance  which is divided into seven steps:

  1. Initial cleaning to inspect and identify abnormalities
  2. Eliminating sources of contamination and inaccessible areas
  3. Establish standards (cleaning, inspection, lubrication)
  4. Train operators
  5. Review and Apply standards, Distribute the tasks
  6. Orderly, clean & Organized Workstation
  7. Making operators more autonomous and Extend participation plant-wide

With Autonomous Maintenance, a team of “owners” of the targeted equipment scrutinizes it and “revamps” it to its original condition … even better.