Total Productive Maintenance (TPM) by Allan Ung


Presentation Description

Training presentation on Total Productive Maintenance (TPM). Includes the concept and management philosophy of TPM, the 8 pillars of TPM activities, TPM implementation strategy, and step-by-step implementation approach. To download this complete presentation, please go to:


Presentation Transcript

Objectives : 

Objectives Understand the concept and philosophy of  TPM as a foundation for Lean Transformation Learn the 8 pillars of TPM activities, TPM implementation strategy, roadmap and step-by-step approach Learn the TPM tools and be able to identify and eliminate loss through TPM implementation Learn how to kick-start TPM deployment with Autonomous Maintenance, Planned Maintenance, Focused Improvement, and Education & Training activities to improve equipment reliability Understand the roles of a TPM implementation organization and the critical success factors Copyrights of all the pictures used in this presentation are held by their respective owners.


Outline Overview of TPM TPM Foundations: 5S & Visual Management TPM Tools Equipment Loss & OEE 8 Pillars of TPM Key Pillars of TPM - Autonomous Maintenance - Planned Maintenance - Focused Improvement - Education & Training Other TPM Pillars TPM Implementation Critical Success Factors NOTE: As this is a PREVIEW , only selected slides are shown. To download the complete presentation, please visit:

From PM to TPM: 

From PM to TPM Modern equipment management began with preventive maintenance and evolved into productive maintenance TPM stands for Total Productive Maintenance – productive maintenance with total participation TPM is team-based productive maintenance – involves every level and every function

Productive Maintenance (“Profitable PM”): 

Productive Maintenance (“Profitable PM”) Preventing breakdowns Designing and installing equipment that needs little or no maintenance Improving or modifying equipment to prevent breakdowns or to make maintenance easier Repairing after breakdowns occur

TPM Principles: 

TPM Principles Increase Overall Equipment Effectiveness (OEE) Provide training to upgrade operations and maintenance skills Involvement of everyone, from top leadership to shop-floor workers A cross-functional approach, involving all departments Implementation through small group activities A fact-based approach to continuous improvement

Why TPM?: 

Why TPM? Avoid wastage in a quickly changing economic environment Producing goods without reducing product quality Produce a low batch quantity at the earliest possible time Reduce cost Goods delivered to customers must be non-defective

TPM Goals: 

TPM Goals Maximize equipment effectiveness Zero breakdowns Zero defects Zero accidents Minimum life cycle cost Zero waste!

Eight Major Pillars of TPM: 

Eight Major Pillars of TPM

Fuguai Tagging (F-Tag): 

Fuguai Tagging (F-Tag) Fuguai Tags are attached to equipment where problems are discovered Two categories of Fuguai Tags: Blue Tag – repairs can be made by operator Red Tag – repairs by maintenance staff Fuguai Register A log for all Fuguai’s issued and resolved

Fuguai Tagging: 

Fuguai Tagging During initial cleaning Afterwards – Everyday process Tag is removed only after the repair is made

One-Point Lessons as a Cascading Training Tool: 

One-Point Lessons as a Cascading Training Tool

Types of One-Point Lessons: 

Types of One-Point Lessons

Loss Structure in Production Activities: 

Loss Structure in Production Activities

Six Big Equipment Losses: 

Six Big Equipment Losses

End of Preview: 

End of Preview To download this entire PowerPoint presentation, please visit : Operational Excellence Consulting