TOTAL PRODUCTIVE
MAINTENANCE
Samed ORHUN
Çağkan ÇELİK
Orçun KIRTIL
Contents
1. What is total productive maintenance (TPM)?
2. Why TPM?
3. History of TPM
4. 8 pillars of TPM
5. Conclusion
What is Total Productive
Maintenance?
Total Productive Maintenance (TPM) is a
maintenance program which involves a newly
defined concept for maintaining plants and
equipment. The goal of the TPM program is to
markedly increase production while, at the same
time, increasing employee morale and job
satisfaction.
 TPM brings maintenance into focus as a
necessary and vitally important part of the
business. It is no longer regarded as a nonprofit activity. The goal is to hold emergency
and unscheduled maintenance to a minimum.
Why TPM?
 TPM was introduced to achieve the following objectives
 Avoid wastage in a quickly changing economic
environment.
 Producing goods without reducing product quality.
 Reduce cost.
 Produce a low batch quantity at the earliest possible time.
 Goods send to the customers must be non defective.
History of TPM
 TPM is a innovative Japanese concept. The origin
of TPM can be traced back to 1951 when
preventive maintenance was introduced in Japan.
However the concept of preventive maintenance
was taken from USA. Nippondenso was the first
company to introduce plant wide preventive
maintenance in 1960.
 In preventive maintenance operators produced
goods using machines and the maintenance
group was dedicated to the work of
maintaining those machines. However with the
high level of automation of Nippondenso,
maintenance became a problem as so many
more maintenance personnel were now
required. So the management decided that
much of the routine maintenance of equipment
would now be carried out by the operators
themselves.
 Thus Nippondenso which already
followed preventive maintenance also
added Autonomous maintenance done
by production operators. The
maintenance crew went in the
equipment modification for improving
reliability. The modifications were made
or incorporated in new equipment.
 This lead to maintenance prevention.
Thus preventive maintenance along with
Maintenance prevention and
Maintainability Improvement gave birth
to Productive maintenance. The aim of
productive maintenance was to maximize
plant and equipment effectiveness to
achieve optimum life cycle cost of
production equipment.
8 Pillars of TPM
 TPM has 8 pillars of activity. These 8
pillars are the following:
 1) focussed improvement (Kobetsu
Kaizen) - Continuously even small steps
of improvement.
 2) Planned Maintenance - It focusses on
Increasing Availability of Equipments &
reducing Breakdown of Machines.
 3) Initial Control - To establish the system
to launch the production of new product
& new equipment in a minimum run up
time.
 4) Education & Training - Formation of
Autonomous workers who have skill &
technique for autonomous maintenance.
 5) Autonomous Maintenance (Jishu
Hozen) - It means "Maintaining one's
equipment by oneself".
 6) Quality Maintenance (Hinshitsu
Hozen) - Quality Maintenance is
establishment of machine conditions that
will not allow the occurrence of defects &
control of such conditions is requored to
sustain Zero Defect.
 7) Office TPM - To make an efficient
working office that eliminate losses.
 8) Safety, Hygiene & Environment - The
main role of SHE (Safety, Hygiene &
Environment) is to create Safe & healthy
work place where accidents do not occur,
uncover & improve hazardous areas & do
activities that preserve environment.
 The Base for the TPM Activity is 5S; Seiri
(Sorting out the required or not required
items); Seition (Systematic Arrangement
of the required items); Seiso (Cleaniness);
Seiketsu (Standardisation); Shitsuke (Self
Discipline).
Conclusion
 Today, with competition in industry at
an all time high, TPM may be the only
thing that stands between success and
total failure for some companies. It has
been proven to be a program that
works.
 It can be adapted to work not only in
industrial plants, but in construction,
building maintenance, transportation, and
in a variety of other situations. If everyone
involved in a TPM program does his or her
part, an unusually high rate of return
compared to resources invested may be
expected.
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