Total Productive Maintenance (TPM)
Structure equipment losses, operator care, inspection standards, planned maintenance and improvement actions around the conditions required for reliable production.
Purpose and method
Structure Total Productive Maintenance activities across autonomous care, prevention and loss elimination.
When to use it
Use TPM for critical equipment where breakdowns, minor stops, deterioration and unclear ownership reduce performance.
Core principle
TPM aims to prevent deterioration and remove chronic equipment losses through shared ownership. Autonomous maintenance does not transfer specialist maintenance work to operators.
What the interactive module provides
- Equipment care plan
- Inspection tasks
- Loss and action overview
- loss profile, autonomous-maintenance standard, planned tasks, abnormalities and improvement backlog
Professional verification: The module supports learning, analysis and documentation. Verify results against actual process conditions, internal standards, safety requirements and competent professional judgement before implementation.
01
Recommended workflow
Structure equipment losses, operator care, inspection standards, planned maintenance and improvement actions around the conditions required for reliable production.
- 1
Restore basic conditions and eliminate contamination sources
- 2
Define safe cleaning, inspection and lubrication standards
- 3
Analyse chronic and sporadic loss mechanisms
- 4
Align planned maintenance with condition and risk
- 5
Verify reliability improvement through stable loss data
02
Practical example
A feeder is reset several times each week. Cleaning restores operation temporarily, but TPM review identifies a contaminated sensor location, missing inspection limit and no escalation criterion.
Calculation or verification principle
Track breakdown frequency, mean time between failures, mean time to repair, planned-maintenance compliance and OEE loss categories. Use consistent event definitions.
Required inputs → Expected outputs
- Required inputs
- equipment hierarchy, losses, failure history, basic conditions, inspection points, maintenance tasks, owners and intervals
- Expected outputs
- loss profile, autonomous-maintenance standard, planned tasks, abnormalities and improvement backlog
03
Common mistakes to avoid
×
Calling routine cleaning a complete TPM system
×
Hiding repetitive resets outside failure data
×
Assigning unsafe technical work to operators
×
Planning maintenance by calendar alone despite condition evidence
04
Frequently asked questions
What data do I need to use this tool?
Prepare equipment hierarchy, losses, failure history, basic conditions, inspection points, maintenance tasks, owners and intervals.
What result does the module produce?
The module produces loss profile, autonomous-maintenance standard, planned tasks, abnormalities and improvement backlog.
Can I implement the result without further review?
No. Treat the output as a structured engineering and improvement aid. Verify source data, assumptions, safety, quality, legal requirements and local process conditions with competent responsible people before implementation.
LEAN Toolbox
Open interactive tool →Total Productive Maintenance (TPM)
Structure equipment losses, operator care, inspection standards, planned maintenance and improvement actions around the conditions required for reliable production.