What is Total Productive Maintenance (TPM)?

What is Total Productive Maintenance (TPM)?

Total Productive Maintenance (TPM) is one of the more advanced Lean Enterprise tools and once Production flow, setup time reduction and good housekeeping are implemented, it becomes important to keep your machinery in the best condition possible.

Running closely in parallel with Practical 5S, Total Productive Maintenance is the process where the operator becomes involved with the regular, daily maintenance of their machine. To begin the targeted machine needs to be thoroughly cleaned and any maintenance issues fixed; the aim is to return the machine to a brand-new condition. As, with all Lean Tools, this is done with a small team of people who know about the machine and it’s maintenance needs.

Once the machine is clean, it becomes easier to keep an eye on it. A list of daily and weekly tasks and checks are made; this may include checking oil and hydraulic fluid levels, and pressure gauges, emptying scrap bin or lubricating. The operator is trained how to safely carry out these tasks. Simple, visual Cleaning Standards are developed and are at hand to assist the operator.

Standard overhaul process for harvest equipment showing the standard work for the TPM procedures to overhaul the harvester.

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To remind the operator to build these tasks into his everyday activities, a Kamishibai or Tee card board is a great way to remind them. This visual board will also assist operators if they rotate positions throughout the week and for supervisors to check these process are complete.

Tee card board showing routine tasks for the TPM team. The columns represent days of the week and cards are turned over from red to green as tasks are completed.

Keeping an eye on our machines and getting the operators involved, through the use of the TPM approach, as well as maintenance, will ensure the machine is running at it’s best. This will improve machine up-time and increased the capacity of your equipment.

Robert Chittenden

Author: Robert Chittenden

Robert Chittenden is a Senior Lean Consultant at TXM Lean Solutions