What are the 8 Pillars of Total Productive Maintenance (TPM)?

What are the 8 Pillars of Total Productive Maintenance (TPM)?

Written by Deepak Bhagat, In Business, Published On
December 18, 2020
Last modified on December 14th, 2021

Research reveals that the average hourly loss for downtime is $260,000. The figures are astonishing as most of the work has already been automated with minimal human intervention, while on the other hand, the figures (loss per hour) have swelled in the recent past and hence could not be ignored at all costs. This is where the 8 pillars of Total Productive Maintenance (TPM) comes into play.

What is TPM and What are the 8 pillars of Total Productive Maintenance (TPM)

Total Productive Maintenance is a maintenance philosophy in which the critical elements in the manufacturing industry are aligned to gain robust, continuous output. The principle stands for perfect production and hence has been divided into eight guiding pillars as suggested by the TPM consultant. The 8 pillars of Total Productive Maintenance (TPM) focuses on preventive and proactive measures that help in the improvement of equipment reliability.

Here Are The 8 Pillars of Total Productive Maintenance –

#1: Autonomous Maintenance

Autonomous maintenance refers to the act that the operators take ownership of their machines. The workers should be trained on routine maintenance like lubricating, inspecting, and cleaning as well. This gives the machine operator a sense of ownership and a complete in-depth knowledge about the machine. On the other hand, it also guarantees that the machine remains clean all the time and is in safe hands.

However, the TPM consultant suggests implementing standards. This involves training the operators to take care of machines based on the manual. Once trained, the operator could autonomously schedule frequent checkups.

#2: Focused Improvement

The word focused improvement derives its origin from the Japanese term “Kaizen.” In manufacturing, the process requires the company to continually grow and experiment to achieve operational efficiency. This is where the concept of Kaizen comes into play. The key lies in working with a small group from a diverse background who focuses on improving the processes. On the other hand, diverse manufacturing teams ensure all the critical parts of the process are taken well care of, and hence brainstorming becomes a critical tool of the methodology.

#3: Planned Maintenance

Next on the list is the planned maintenance. The process consists of studying the history of downtimes and failures, and thus, helping in the prediction the same. Scheduled maintenance ensures that the machines are taken well care of and hence decreases the downtime. On the other hand, it lets users know when the maintenance is about time and hence keeps the product piled up before time.

This ensures that there is no delay in production. Furthermore, by proactive scheduled maintenance, one could ideally schedule maintenance when most of the machines have minimal use or is ideal completely.

#4: Quality Maintenance

Despite the scheduled planning and regular checkups, the work is futile until it provides quality maintenance. This ensures that all the components produce accurate results no matter what. On the other hand, the biggest advantage of quality maintenance is that it eliminates low-quality output and helps in error detection as well. Also, this ensures errors are minimized and completely eliminated in the process.

#5: Early Equipment Management

The following TPM methodology plays a pivotal role and is considered to be the most important method from the 8 pillars of Total Productive Maintenance (TPM), as in this step, the machine obtained for the manufacturing process on the application of Total Productive Management is carefully studied, and changes are made in the design of the machine as per the needs. Understanding the needs of people who interact with the machines regularly definitely helps.

This thus could help in the ease of working and maintaining the machine. Major additions would include better accessibility of parts, comfort for the operator, and increased manual efficiency.

#6: Training and Education

Without the right guidance, it becomes critically impossible for everyone in the hierarchy to operate. continuous improvement consulting training on all levels ensures that the company is updated by all the latest practices. On the other hand, if you do not follow the latest updates, it becomes certain that your program will fail. The aim of such a program is to identify tasks, and the program is to identify gaps and fulfill them. The following principle helps in the long run and can prove to be a disaster for the company in the long run.

#7: Health, Safety, and Environment

Apart from the obvious reasons, a safe environment is the need of the hour. Employees dedicate their life struggling to build and run a company seamlessly, and hence it becomes essential for companies to provide that environment that keeps them afresh while taking care of the health and safety needs. On the other hand, stringent laws imposed by governments focus on the safety of the employees as well. Companies need to invest in the creation of a positive environment that fulfills all the criteria of the governing body.

#8: TPM in Administration

Last but not least from the 8 pillars of Total Productive Maintenance (TPM). The role of the Total Project Management process is to eliminate all the undesired functions or processes out. This does not limit the mean optimization of processes only. Undesired or unnecessary administrative functions also need adaptions in the current time and hence could not be ignored at all costs. This means that there is room for growth in administrative functions like order processing, scheduling, and procurement of goods. To add more to it, the aim of TPM is to streamline processes and make the entire process waste-free as well.

For instance, order through a streamlined order processing procedure can provide the raw materials at the right time and get them manufactured and delivered without any hassle.

Concluding Remark

The concept of TPM dates back decades and hence could not be ignored. The procedure takes care of the needs at all levels and hence could not be ignored at all costs.

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