What is TPM (Total Productive Maintenance)?

Total Productive Maintenance (TPM) is an all-inclusive approach to equipment maintenance that strives to achieve perfect production (zero defects).  This means that equipment is expected to have zero breakdowns, slow runs, or defects.  TPM also values a safe working environment with a zero accident policy.
TPM is a concept with the aim to maximize the productivity of facilities by transferring the responsibility for regular maintenance to employees.  It consists of 8 pillars, each containing approaches to eliminate losses and waste.  The TPM Concept certification, offered exclusively through the Management and Strategy Institute, is designed to demonstrate the basic concept of Total Productive Maintenance and test you on those concepts.

Goal of Total Productive Maintenance (TPM)

TPM ams at :

1.Restructuring the corporate culture through improvement of human resources and plant
equipment.

2.Creates a bright, clean, pleasant factory.

3. Means to reinforce people and facilities, resulting in a invigorated organisation.

4. Improves “Overall Equipment Effectiveness”.

5. Improves “Cross Functional Working” by eliminating departmental walls.

6. Makes possible “Man-less Operation”, “Factory-operation

7. Makes “Lean-Production” and “JIT” possible.

TPM have 3 basic goals – Zero Product Defects, Zero Equipment Failures and Zero Accidents is set to achieve these goals by Gap Analysis of previous historical records of Product Defects including customer complaints, Equipment Failures and Accidents. A clear understanding of this Gap Analysis through Cause-Effect Analysis, Why-Why Analysis, and P-M Analysis and other tools are used to plan a physical investigation to discover the weak areas.

Many companies struggle to implement TPM due to 2 main reasons:

  • First is having insufficient knowledge and skills especially in understanding the linkages between the 8 Pillar-Activities in TPM.
  • The second reason is that TPM requires more time, resources and efforts.

Overview

This practical activity takes a progressive approach to applying TPM in a manufacturing environment. Building on the basic concepts at the heart of TPM the course gives a clear understanding of how TPM can develop into a company-wide Improvement programme.

Course Structure

The course is based around a simulated manufacturing process. This enables the practical application of the structured approaches covered during the course. The activity builds logically showing the cumulative effect of TPM which will aid application.

Who Should Attend

The course is suitable for delegates wanting to gain a detailed understanding of the concepts, structure and approach to TPM. It is aimed at those directly involved in the application of TPM. Ideally the company will have decided it intends to adopt TPM and candidates will understand the roles and responsibilities at all levels in the organisation.

Topics Covered

  • The concepts of TPM
  • 12 steps of deployment
  • Overlapping small groups
  • The 8 Pillars of TPM:
    • Focussed Improvement
    • Autonomous Maintenance
    • Planned Maintenance
    • Training and Education
    • Early Equipment Management
    • Quality Maintenance
    • Office TPM
    • Safety, Health and Environment

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