Saturday 1 December 2018

Total Productive Maintenance (TPM) as a Practical Repair Method

Total Productive Maintenance or TPM is one method of maintenance process developed to increase productivity in the work area, by making the process more reliable and less waste. This method is part of Lean Manufacturing.

TPM serves to maintain the plant and its equipment to always be in top condition. To meet this objective, a preventive and predictive maintenance is require. By applying the principle of TPM we can minimize the damage to the machine. Problems common to machines such as dirty, nuts and bolts disappear, oils are rarely replace, leaks, abnormal sounds, excessive vibrations, dirty filters, etc. can be minimize by TPM.


Indeed, the neglect of machinery is more often cause by the lack of involvement of operators in maintaining machines, and tends to hand over all maintenance problems to maintenance staff. The TPM principle says that the operator should be able to perform minor maintenance and repair in case of problems with the machine.

The operator must also have some maintenance skills. Thus, problems with the machine can be resolve before the problem becomes complex. Reliance on maintenance staff can be reduce, so maintenance only focuses on addressing larger issues only.
Total productive maintenance has a complete definition contains five very important things in maintenance, namely:

  • Maximize the effectiveness and efficiency of the overall equipment/ machine.

  • Doing it preventive maintenance which comprehensive all age tool.

  • Involves the entire Department good planners, users (user), as well as keeping tools.

  • Involve all employees from top management to the front line – worker (worker).

  • Developing preventive maintenance management motivation through small group activities namely the independently.

Of the five terms above can be define namely Total Productive Maintenance (TPM) is an approach in the field of maintenance updates which optimize the effectiveness of the whole equipment, reduce damage and increase the maintenance of independent operators through daily activities that cover all workers in all departments of all levels.

Total Productive maintenance implementation

For TPM implementation, production and maintenance units must work together. Its implementation will involve all employees in the maintenance of machinery, equipment and aims to increase productivity. The success indicators of TPM implementation are measure by OEE (Overall Equipment Effectiveness) and its parameters include various losses that occur such as downtime, changeover, speed loss (machine slowdown), idle (idle machine), stoppages (engine stop), startup (machine turned on / on), defect and rework.

As discussed earlier, accurate and practical TPM implementation will increase productivity throughout the organization.
The more detailed benefits of TPM applications are:

  • A business culture design to sustainable improve the efficiency of the total production system.

  • The application of a standardize and systematic approach, in which all losses are well anticipated.

  • All departments that have an influence on productivity will have a predictive mindset against productivity barriers.

  • Organizations that are transparent to zero losses.

Improvement measures with TPM should be run as an ongoing process, not just as a short-term menu. Ultimately, TPM will provide a practical ability for the company to call for operational excellence.

TPM Analysis

TPM strives on enhancement time value added operator taking six large losses, which lowers the productivity of workers and equipment and create waste. Losses – losses are: damage to equipment, organize and customize, idling and minor stoppages, reductions in speed, reduction results, and generations of quarrel.

  • The first two lost is "loss of time" and is use to evaluate the availability of "(A)".

  • The third and fourth losses is "loss of speed" and is use to determine the "efficiency performance (P). While the fifth and sixth is a loss "level of quality (Q)".

  • When A is the ratio of net operating time during loading, net operating time = time loading-damage and adjustment. Loading time = plan production break-time – the time of plan maintenance.

  • P is the ratio of the actual production achieve compare to the amount of production expect at the given time.

  • Q is the ratio of the number of good product compared to the overall production that is produce at a given time.

Based on the evaluation of loss the above losses, overall equipment effectiveness (OEE). The OEE indicates the scope of the increase productivity available in a process. The assumption that a process consists of eight hours of the time of loading, each an hour to damage and adjustment, among 500 part produce by a machine with high capacity of 100 parts/hour, 50 part will be disable and 50 machine parts reset.


Then the value of A is 75%, 83%, P Q 80% OEE, and only 50% (OEE = A x P x Q). Thus the productivity can be doubled in the process by getting rid of the loss-loss, as shown in the following figure.

Implementation of TPM include eight fundamental development activities:

  • Focusing on the improvements design to reduce the harm target by the groups cross-function; autonomous maintenance with include operators in the treatment of assets;

  • Maintenance planned by designing an adequate prevention and maintenance plans that are predictive;

  • Education and training by designing development programs related to skills-related equipment;

  • Early equipment management that is easy to be kept;

  • Maintenance of quality which ensures the production of free handicap;

  • Include supporting divisions by streamlining the flow of information;

As well as ensuring security and environmental management through maintenance of assets. TPM has been implement with success in different industries around the world. The gains that have been achieve as a form of productivity, improvement of quality, cost, delivery increase emphasis, better security and integrity of the environment, as well as increase employee moral. As many as 120 organizations manufacturing in India has been implementing TPM.

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