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What is TPM – Total Productive Maintenance

Making assets work to add value. To keep value flowing, and maximize your sales and margin contribution, you must engage everyone in establishing and maintaining equipment and process reliability.

Establishing Stable and Reliable Processes and Equipment.

Today’s operating environment demands predictable equipment performance. A company cannot become lean, or sustain their lean efforts, absent of reliable processes and equipment. In that context, TPM is a well-disciplined program targeting zero losses and the highest level of reliability and capability.

Having fully reliable equipment is a pre-requisite for meeting customer demand, on-time, as planned. The overall competitiveness of your organization depends on establishing stable and reliable processes and equipment. That’s what TPM does.

A TPM program is strategic, systemic and comprehensive, with multiple pillars of application. Its strength lies in the sum of its parts.

Its implementation is an organizational process, supported and reinforced by leadership and management.  TPM fosters continuous and rapid improvement through employee involvement, team structures, and a closed-loop measurement of results to ensure long term equipment performance. TPM is a primary enabler to maximizing your return-on-assets.

In the mid-eighties, our consultants were trained by the Japanese TPM masters and based on our years’ of TPM deployment, we have developed a systemic approach to implementation which begins with organizational readiness and current-state analysis and moves into planning and execution.

Along the way, we educate management and associates in the TPM methodology, create leader standard work routines and an auditing process that ensures the program is continually moving forward and is sustainable over the long term. Throughout the TPM implementation we develop your internal TPM capabilities so you have ownership of the transformation process.

For more than 35 years, Productivity Inc. has worked with leadership in most every industry implementing TPM. For those looking to leverage our experience, give us a call. We’ll be happy to provide you with additional information on our TPM Rollout and discuss how your TPM return-on-investment can be multiple times our fees.


TPM Case Study 

Stabilize and Reduce Maintenance Cost

Company: Large Sodium and Boron Mining Operation

Engagement: 2 years

Objective: Stabilize and reduce maintenance cost consistent with EH&S standards; increase capacity; lower COGS

Approach:

  • Facilitate Total Productive Maintenance (TPM) Action Planning and design of TPM Roll-Out Plan
  • Certify 4 TPM/Autonomous Maintenance trainers
  • Consult and coach on storeroom redesign, maintenance scheduling and work order system, maintenance auditing, mistake-proofing, and quick changeover principles

Outcome: 

  • Maintenance cost reduced substantially over previous period
  • Productivity (sales per employee) improved by 30%
  • $1.6 million energy savings (leaks eliminated).

TPM Case Study 

Build Internal Autonomous Improvement Capabilities

Company: Largest Integrated Energy Company in Canada

Engagement: 5 years

Objective: Build internal Autonomous Improvement capabilities

Approach:

  • Co-design a Lean Learning curriculum
  • Lead numerous Mistake Proofing, AI, SMED, TPM, and 5S kaizens
  • Tailor in-house transfer of learning to accommodate varying processes
  • Certify Lean Trainers
  • Consult and coach on Leadership Standard Work
  • Consult, coach, and mentor on project management

Outcome: Results confidential


TPM Case Study 

TPM Implementation

Company: Manufacturer of Building Products

Engagement: 4 years

Objective: Implementation of Total Productive Maintenance; 4 SBU’s and 25 locations

Approach:

  • Facilitate design and implementation of a TPM Roll-Out Action Plan
  • Lean Leadership Development Program
  • Customize training programs to support a systemic TPM Roll-Out process
  • TPM coaching, tool-specific training, and audit process

Outcome: Results confidential

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