Similar to TQM (Total Quality Management) and TPS (Toyota Production System), Total Productive Maintenance (TPM) originated in Japan, and shares many of the same principles. Usually, when people say “TPM”, they usually mean “a good maintenance system”. However, TPM is actually a particular approach to maintenance.
Essentially, the idea behind TPM is to get everybody in the factory involved with maintenance. According to Seiichi Nakajima, who is considered the father of TPM:
TPM is a company-wide program for improving equipment effectiveness—something maintenance alone could not do. When TPM came to America, we realized we probably made a mistake calling it Total Productive Maintenance. Probably should have been Total Productive Manufacturing.
TPM expands on maintenance and preventive maintenance concepts by integrating all departments and individuals inside a company. Even with limited resources, enhancing overall performance is possible with an organization-wide approach centered on taking responsibility for the machines and equipment.
5S is a systematic process through which employees make space, set the tools, materials, and equipment in order, – ‘a place for everything and everything in its place’ – and regularly clean and inspect the tools and equipment.
5S is a great basis for a TPM implementation. It helps give a purpose to the 5S efforts, which often sees great resistance and is always at risk of being abandoned.
With a properly implemented 5S system, you will have the foundation for an autonomous maintenance system in place.
To implement an autonomous maintenance system, you will need to follow these steps:
Want to know how a preventive maintenance system helps cut costs and increase productivity? Click below.