Total Productive Maintenance and OEE Systems

Total Productive Maintenance (or TPM) is a long established Japanese process focused on improving productivity and reducing waste. With Total Productive Maintenance the machine operator is trained in fault finding and simple maintenance. Teams known as “zero defects” teams try to minimise defects and issues. These teams are made up of experts and normal workers.

The workers then glean knowledge and expertise and are the able to give a higher contribution. If defects and machine downtime are reduced the results from your OEE Systems will be improved.

TPM’s Other names

TPM can also stand for “Total productive Manufacturing” and “Total process Management”. It is basically deterioration management. A well-known motto with TPN is “zero error, zero work-related accident, and zero loss”.

The three goals of Total Productive Maintenance

1. Zero product defects
2. Zero equipment unplanned failures
3. Zero Accidents

The first step is to look back at plant history, lean manufacturing fugues and OEE Systems. These are analysed and then a plan to move forward is made. You just have to look at the card and the map analogy. You can only plan a route once you have a destination and when you know where you are leaving from.

Total Productive Maintenance and the 6 big losses

The 6 big losses are as follows:

1. Set up and initial adjustment time
2. Equipment breakdown time
3. Idling and minor losses
4. Speed and cycle time losses
5. Start-up quality losses
6. Process quality losses

Total Productive Maintenance and its 8 Pillars

The 8 Pillars of Total Productivity Maintenance are as follows

1. Focused improvement
2. Autonomous Maintenance
3. Planned Maintenance
4. Training and education
5. Early phase management
6. Quality maintenance
7. Office Total productive maintenance
8. Safety, Health and environment.

Such manufacturing processes and analyses such as Total Productive Maintenance and OEE won’t be useful to every business in manufacturing. You must assess your specific needs and requirement. Obviously in every business there is need for waste reduction, trained employees and maximal productivity.

The basics and principles of these processes, however, can be taken and applied.
OEE Systems will measure your overall equipment effectiveness on a stand-alone basis but it is much more powerful when used in conjunction with other processes like Total Productive Maintenance and Kaizen. They are powerful together!

For more information see OEE Systems