We offer specialized training services designed to help organizations in proper maintenance of machines and equipment to improve machine capability, reduce breakdowns and downtime. Our training programs support your journey towards continuous improvement and increase efficiency and productivity resulting in sustainable, safe, and compliant work environment.
Total Productive Maintenance (TPM) is a comprehensive approach to equipment maintenance aimed at achieving zero breakdowns, zero defects, and zero accidents in production. It integrates proactive and preventive maintenance strategies with employee involvement to maximize Overall Equipment Effectiveness (OEE) and enhance productivity.
Objectives of TPM
- Maximize equipment efficiency by minimizing downtime and defects.
- Increase productivity through better machine utilization and reduced waste.
- Improve workplace safety by ensuring proper maintenance and reducing hazards.
- Empower employees by involving them in autonomous maintenance.
- Enhance product quality by eliminating equipment-related defects.
8 Pillars of TPM
- Autonomous Maintenance – Train operators to perform basic maintenance and inspections.
- Planned Maintenance – Implement preventive and predictive maintenance strategies.
- Quality Maintenance – Eliminate defects by addressing root causes of failures.
- Focused Improvement (Kaizen) – Continuously optimize equipment performance.
- Early Equipment Management – Design and install machinery for maximum reliability.
- Training & Education – Develop skills to enhance maintenance knowledge.
- Workplace Safety & Environment – Promote a clean, safe, and organized workspace.
- Office TPM – Extend maintenance principles to administrative functions for efficiency.
TPM & Overall Equipment Effectiveness (OEE)
OEE Calculation:
OEE = Availability × Performance × Quality
- Availability – Measures uptime vs. planned production time.
- Performance – Evaluates speed and efficiency of machines.
- Quality – Assesses defect rates and rework needs.
Benefits of Implementing TPM
- Reduced Equipment Breakdowns – Preventive maintenance minimizes unexpected failures.
- Increased Equipment Efficiency (OEE) – Higher uptime, productivity, and reliability.
- Lower Maintenance Costs – Reduces repair expenses and extends equipment life.
- Improved Product Quality – Fewer defects due to well-maintained machines.
- Higher Employee Involvement & Ownership – Operators take responsibility for equipment health.
- Enhanced Workplace Safety – Minimizes accidents through proper maintenance.
