Published: May 27, 2025  Updated: May 27, 2025

Total Productive Maintenance: Shifting Your Approach to Equipment Excellence

When answering the question of what is total productive maintenance (TPM), we can't look at it as just about keeping the machinery running. Instead, you must take a step back and consider it a mindset. Everyone in the company should have this "culture shift" that involves everyone in an organization, from the CEO to the shop floor.

Think of it as a marathon, not a sprint, where you want to wring every last drop of efficiency and quality out of your equipment. In this article, we'll look at the definition, the benefits and challenges, industrial examples, eight foundational elements, and how a computerized maintenance management system (CMMS) brings about better success.

Understanding Total Productive Maintenance (TPM)

This approach involves every employee in improving equipment effectiveness. Your goals include eliminating losses, increasing productivity, and extending equipment life. This concept moves a company away from a "reactive" mentality. This thinking means you only tend to assets when they fail or break down.

Instead, TPM focuses on preventing breakdowns, improving performance, and creating a workplace where everyone takes ownership of equipment.

Benefits of Total Productive Maintenance for Your Organization

You can easily see the benefits of TPM. First and foremost, it boosts productivity. When equipment operates smoothly and efficiently, output increases.

Second, it improves quality. By preventing breakdowns and reducing defects, the asset creates a better product.

Third, it extends equipment life. Proper maintenance means your machinery lasts longer, saving you money on replacements.

Fourth, you have efficient resources and energy usage. You don't have as many glitches, mishaps, or "glitches."

Finally, it creates a safer work environment. TPM emphasizes identifying and eliminating potential hazards.

Overcoming Common TPM Challenges

To achieve the above, you have to overcome obstacles. I mentioned one from above. It requires a significant cultural shift, which can be tough to achieve. If you look to completely change maintenance operations or want to improve upon existing strategies, some employees might resist the change.

The entire concept of change presents its own challenges both for work life and home life. For suggestions on productive change, visit ComCare.

It also demands a substantial investment of time and resources in training and implementation. This holds true when you make a complete change from reactive to proactive. Laying out the goals and clearly communicating them with your employees eases the tension during the change.

Because of this, you might not see a substantial return on investment in the short term. And, let's face it, it can be difficult to measure the return on investment in the short term. Again, as seen above, you look for long-term, sustained benefits.

Discover how streamlined maintenance processes can elevate production. Learn more.

Real-World TPM Examples from Manufacturing and Healthcare

To see TPM in action, let's look at two industries.

Manufacturing

Imagine an automotive plant where they operate fully under TPM. Employees can stop the line if they see a problem. This leads to immediate fixes and preventing defects. Workers constantly look for ways to improve equipment performance.

Healthcare

Hospitals have complex equipment critical to patient care. By implementing TPM, the staff reduces downtime, improves patient safety, and optimizes resource utilization. For example, a hospital might use TPM to increase the lifespan of imaging equipment. This increases the availability and reliability of the asset.

The 8 Foundational Pillars of Total Productive Maintenance

When you look to moving into TPM, you should discuss the following components. All must work together to achieve success.

Administration & Goal Setting for TPM Success

Administration involves setting the stage for success by establishing clear goals, policies, and procedures. The people involved create a supportive environment for TPM initiatives. What to include:

• Planning and organizing TPM activities. Developing a roadmap for TPM implementation, setting clear objectives, and allocating resources.
• Building a TPM team. Creating a cross-functional team with representatives from different departments to drive the initiative.
• Communicating the TPM vision. Effectively communicating the benefits of TPM to all employees and gaining their buy-in.
• Performance measurement. Establishing key performance indicators (KPIs) to track progress and measure the impact of TPM.

Continuous Improvement Through Kaizen & Standardization

Continuous improvement lies at the heart of TPM. Here, you focus on identifying and eliminating losses, increasing efficiency, and enhancing overall equipment effectiveness. Activities include:

• Kaizen event. Conducting focused improvement activities to address specific problems or opportunities.
• Standardization. Developing and implementing standard work procedures to ensure consistency and efficiency.
• Problem-solving tools. Using tools like root cause analysis, 5 Why's and fishbone diagrams to identify and address issues.
• Innovation. Encouraging a culture of creativity and experimentation to find new and better ways of working.

Creating a Safe and Healthy TPM Work Environment

You must have a safe and healthy workplace for TPM success. Include the following:

• Safety audits and inspections. Regularly assessing workplace hazards and implementing corrective actions.
• Safety training. Providing employees with the knowledge and skills to work safely.
• Ergonomics. Designing workspaces to minimize physical strain and discomfort.
• Emergency preparedness. Developing and practicing emergency response plans.

Building Quality Into Every Process

TPM and quality go together. You build quality into the production process and eliminate defects. Suggestions:

• Quality control. Implementing quality control measures to prevent defects from occurring.
• Statistical process control (SPC). Using statistical methods to monitor and control process variation.
• Mistake-proofing. Designing equipment and processes to prevent errors.
• Customer satisfaction. Focusing on meeting customer needs and expectations.

Workforce Training and TPM Education

A skilled and knowledgeable workforce means employees perform their jobs effectively. Key activities include:

• Operator training. Equipping operators with the skills to perform basic maintenance tasks and troubleshoot equipment issues.
• Maintenance technician training. Providing advanced training for maintenance personnel.
• Leadership development. Developing leaders who can champion TPM and drive change.
• Continuous learning. Creating a culture of lifelong learning and development.

Ready to revolutionize your maintenance department? Schedule a live demo today.

Preventative Maintenance as the Cornerstone of TPM

What is total productive maintenance without this piece? Preventive maintenance sits as the cornerstone of TPM. This pillar focuses on preventing equipment failures through regular inspections, maintenance, and repairs. What PMs should you do?

• Equipment inspections. Conducting regular inspections to identify potential problems.
• Lubrication. Implementing a lubrication program to prevent equipment wear.
• Spare parts management. Maintaining an adequate inventory of spare parts.
• Predictive maintenance. Using technology to predict equipment failures.

Early Equipment Management for Long-Term Efficiency

This focuses on selecting and installing equipment that exhibits reliability, maintainability, and efficiency from the outset. What should you consider?

• Equipment selection. Carefully evaluating equipment options based on performance, reliability, and maintenance requirements.
• Equipment installation. Ensuring proper installation and commissioning of equipment.
• Equipment design. Working with equipment manufacturers to incorporate maintainability features into equipment design.

Empowering Operators with Autonomous Maintenance

Autonomous maintenance empowers operators to take ownership of equipment care. This involves training operators to perform basic maintenance tasks and conduct regular equipment inspections. Benefits include:

• Increased equipment uptime. Operators can quickly identify and address minor issues.
• Improved equipment performance. Operators develop a deeper understanding of their equipment.
• Enhanced employee engagement. Operators feel more invested in the equipment's performance.
• Reduced maintenance costs. Fewer breakdowns and less reliance on maintenance technicians.

How a CMMS Enhances Total Productive Maintenance

How does computerized maintenance management system (CMMS) software help your TPM program?

Asset Management

Asset Management - A centralized database for all your asset records and information. You have numerous key performance indicators (KPIs) to shape your program.

Preventive Maintenance – Create your PM list through both manufacturer suggestions and maintenance history. Note priorities and cycles of PMs.

Work Order Management - You standardize your work order and track open, closed, and backlogged jobs.

Reports – Beyond KPIs, you have reports for inventory, work orders, labor, and so much more.

Total Productive Maintenance Works– When Everyone's Involved

For TPM to work, you should have every employee involved. Some will conduct direct maintenance. Some will operate the assets. Others may run across issues and submit work requests. Not everyone has to know the inner workings of all assets. However, everyone should strive to understand when something looks out of place or wrong.

TPI consists of several components, all should work together for the company's success. You should also consider adding a CMMS to the mix for better organization.

Mapcon Technologies offers a world-class system. 800-922-4336.

Ask for a free demonstration on how MAPCON helps your total productive maintenance.