Total Productive Maintenance (TPM)
Increasing Overall Equipment Effectiveness (OEE) and maximising the value of your capital investments.
Achieve Manufacturing Excellence with TPM
What is TPM?
Total Productive Maintenance (TPM), as a Lean Manufacturing methodology, is a company-wide initiative for maximizing the effectiveness and longevity of equipment.
The goal of the TPM program is to significantly increase labor and capital productivity while, at the same time, increasing employee morale and job satisfaction.
TPM brings equipment management into focus as a necessary and vitally important part of the business.
Targeted at all levels of the organization, TPM and its eight pillars provide the necessary process and tools to achieve zero defects, zero breakdowns and zero accidents.
To increase Overall Equipment Effectiveness (OEE), the six major equipment losses have to be eliminated
TPM Training Programs
The TPM Excellence Award is conferred by the Japan Institute of Plant Maintenance (JIPM) to recognize organizations that have attained a high level of manufacturing excellence. The TPM excellence initiative helps organizations to know where they are on the excellence journey and what they need to do to achieve a higher level of performance.
This is done through a thorough assessment of organizational performance against the requirements of an internationally benchmarked TPM excellence framework.
The TPM Self-Assessment Guide & Tool will help you to get an accurate snapshot of your current state of TPM implementation and facilitate you to chart action plans to achieve the future state.
The Autonomous Maintenance (AM) audit system assesses the progress made by production teams toward achieving the company's TPM goals. AM audits also expose weaknesses in the operators' knowledge, skills and equipment maintenance capability.
The Autonomous Maintenance audit step-by-step checklists are based on the TPM Excellence Framework. It consists of 6 checklists covering steps 1 to 6 of the AM pillar.
The AM audit checklists will help TPM teams to move up the AM pillar in a systematic step-by-step process to achieve reliability excellence.
Increase your ROI with TPM Implementation
Our manufacturing excellence approach helps our clients improve the return on their capital investments in two ways:
1. Maximizing the value of equipment and increasing the predictability of their outcome
Our TPM consultants are JIPM-certified and we work closely with organizations to achieve higher lifecycle returns for their capital investment, in less time and with greater predictability, by taking a holistic approach to Overall Equipment Effectiveness (OEE) improvement. We have also worked with the semiconductor industry in applying the SEMI E10 standard to improve OEE.
We ensure the OEE is significantly improved with a sharp view on value and risk by:
Aligning goals and metrics to foster a culture of collaboration between maintenance and production teams
Utilizing visual dashboards and asset analytics to provide critical indicators impacting performance
Enabling maintenance and production employees on the TPM principles and applications for shop-floor manufacturing excellence
Identifying the major equipment losses that offers the highest value potential
Facilitating maintenance and production teams on elimination of the major equipment losses, such as reducing operating costs by reducing/eliminating unplanned downtime
Establishing and implementing a clear stakeholder communication strategy early in the process
Developing the optimal resource strategy for the maintenance function
2. Providing organizations an unbiased assessment of the current state manufacturing excellence based on the JIPM TPM excellence criteria
To help companies apply analytical rigor to manufacturing excellence, we have established an assessment system based on the JIPM TPM excellence criteria.
At the heart of this approach is the TPM assessment system, which evaluates ten dimensions of manufacturing excellence:
Policies and objectives
Product and equipment development and control
Training and development
Administrative and supervisory departments
Safety, sanitation and environmental control
Effects and evaluation
The outcome of this diagnostic is a visual scorecard that shows our clients exactly which aspects of their TPM performance are sufficiently advanced and which require improvement.
The scorecard ensures that decision making is more transparent and based on accurate facts since it highlights the critical gaps that must be addressed before the project is ready for successful execution.