What is TPM?

TPM, or Total Productive Maintenance, is a maintenance program that combines equipment maintenance with the manufacturing process. TPM was originally created by Seiichi Nakajima in Japan and was first implemented in 1971 by Nippondenso, a Toyota parts manufacturer. It has since been adopted and adapted by various organizations.
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Since production relies so heavily on machines and equipment to get jobs done, the losses that can occur from any of the machines or equipment malfunctioning leads to a loss in productivity and money. TPM aims to minimize losses, increase production, and create higher job satisfaction by adopting a unique system which involves production operators in the maintenance process.

There are 6 main losses that TPM focuses on reducing:

1. Equipment Failure
2. Setup and Adjustments
3. Idling and Minor Stops
4. Reduced Speed
5. Process Defects
6. Startup Rejects

TPM aims to eliminate these losses by implementing the 8 pillars of TPM, which are:

1. Autonomous Maintenance
2. Focused Improvement
3. Planned Maintenance
4. Quality Maintenance
5. Early Equipment Management
6. Training & Education
7. Safety, Health & Environment
8. Total Productive Maintenance in the Office

​Why should you care?

TPM can reduce manufacturing costs by 30% and can also increase Overall Plant Efficiency (OPE). Aside from manufacturing costs and efficiency, it also saves time lost by trying to get a broken or idling machine moving. Most importantly, it helps the business run more smoothly, while also boosting morale and increasing safety for employees. Reducing the frustration placed on workers creates a better work environment and increases productivity. The focus on efficiency, equipment maintenance, and the employee satisfaction is what makes TPM a viable maintenance program to use in the production process.