Total Productive Maintenance

Total Productive Maintenance (TPM)
Lean Manufacturing | Lean Consulting

Total productive maintenance (TPM) is a critical component in the lean manufacturing process, as it helps to ensure equipment availability, speed and performance. Unlike the traditional “run to failure” model of equipment maintenance – wherein a company runs its equipment until it breaks – TPM emphasizes the need to fix potential problems before they cause downtime. Lean Synergy International (LSI) will help your company implement a comprehensive total productive maintenance plan that will keep your equipment running at optimal condition.

TPM: Measuring Results

In order to measure how effective your current equipment maintenance plan is, you first need to look at two factors:

• MTBF, or mean time between failures, and
• MTTR, or mean time to repair.

MTBF measures how effective repairs are by recording the amount of time between when a machine is fixed and when it breaks down again. MTTR measures how long a machine is down while maintenance performs its repairs. Their relationship to each other is significant; for instance, if your MTTR is only two hours but your MTBF is one week, the speediness of your repairs is being undercut by how often you need to make them. By implementing TPM as part of your overall lean manufacturing plan, you will be able to keep your equipment up and running for longer periods of time – without increasing the time it takes to make repairs.

Autonomous Maintenance and TPM

So just how does total productive maintenance work as part of a lean manufacturing model? In a nutshell, TPM shifts the maintenance paradigm from running equipment until it breaks to inspecting, diagnosing and correcting small issues on a daily basis. This is accomplished in large part by entrusting operators with greater responsibility for the equipment they handle. In the lean consulting industry, this is referred to as “autonomous maintenance” and it, along with planned maintenance, makes up the cornerstone of TPM.

Autonomous maintenance begins with LSI teaching your operators how to perform daily inspections on their equipment. Your operators then become your first line of detection for potential problems, and are able to provide maintenance with valuable information that can help prevent equipment failures. Planned maintenance is also scheduled on a regular basis to correct for normal wear and tear before it causes downtime.

Measuring OEE for Lean Manufacturing Success

The true measure of your company’s TPM is its overall equipment effectiveness, or OEE. OEE looks at the three determining factors in equipment effectiveness:

• Reliability: how reliable is your equipment during its operating period? Does it break down a lot?
• Performance: when your equipment is running, how efficient is it? Can it run at the fastest speed prescribed by the manufacturer?
• Quality: is your equipment producing perfect quality products?

As part of a lean manufacturing model, TPM will help maximize your equipment’s uptime, efficiency and output so that you can experience a true transformation on your production floor. To learn more about how LSI can help your organization maximize overall productivity, contact them for a quote at