What is Total Productive Maintenance?
Total Productive Maintenance (TPM) is a process to maximize the productivity of your equipment for its entire life. TPM fosters an environment where improvement efforts focus on safety, quality, delivery, cost and creativity, and the participation of all employees is encouraged.
The goal of TPM is to maximize your Overall Equipment Effectiveness (OEE) and to reduce equipment downtime to zero while improving quality and capacity.
Benefits
of Total Productive Maintenance
Typical manufacturing operations have experienced improvements in the following areas in a relatively short period of time (6-12 months) through the implementation of TPM:
- Overall Equipment Effectiveness (capacity) improvement of 25-65%
- Quality improvement of 25-50 %
- Maintenance expenditure reductions of 10-50%
- Percent planned vs. unplanned maintenance increase of 10-60%
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Successes
A tool manufacturer implemented TPM to improve the productivity of equipment. They were implementing Lean, attempting to use flow processes, but were having difficulty because of the poor uptime (capacity) of their equipment. Within 18 months they saw a 15% increase in equipment productivity. What they were not expecting was a $1,200,000 reduction in their maintenance budget (repair parts), including a $50,000 reduction in oil usage (reduced leaks), a $56,000 reduction in water usage (leaks and modifications), and a $57,000 reduction in contract maintenance.
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