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Last updated on 2024年12月6日

How do you sustain and audit the results of TPM and avoid backsliding or complacency?

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Total Productive Maintenance (TPM) is a systematic approach to optimize the performance and reliability of your equipment and processes. It involves the participation and collaboration of all employees, from operators to managers, in identifying and eliminating waste, defects, and breakdowns. TPM can help you achieve higher quality, lower costs, and improved customer satisfaction. But how do you ensure that the benefits of TPM are sustained and audited over time, and that your organization does not fall into the trap of backsliding or complacency? Here are some tips and best practices to keep your TPM program on track and effective.

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Paulo Canario

JIPM TPM Instructor #167 Sócio-gerente Fact Consulting
Mário Marques Júnior

Diretor Industrial | Gerente industrial | Gerente de Manuten??o e Utilidades | Gerente de Produ??o Industrial |…
Asanka Chathuranga MBA, BSc.(Eng.), CLSSBB

IWS(RTT) Expert | Breakthrough results in 04 manufacturing pilot sites, 09 global deployments in 2+ years | Bottom-line…

1 Establish a TPM policy and vision

The first step to sustain and audit the results of TPM is to have a clear and shared policy and vision for your TPM program. This should define your goals, objectives, and expectations for TPM, as well as the roles and responsibilities of each team and individual. Your TPM policy and vision should be aligned with your business strategy and customer needs, and communicated widely and frequently to all stakeholders. You should also review and update your TPM policy and vision regularly, based on the feedback and data from your TPM activities and audits.

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Mário Marques Júnior

Diretor Industrial | Gerente industrial | Gerente de Manuten??o e Utilidades | Gerente de Produ??o Industrial | Opera??es | Planejamento | Manufatura | Engenheiro Mecanico | Engenharia Industrial | TPM
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Para auditar e sustentar os resultados do TPM , estabele?a indicadores-chave de desempenho (KPIs) claros e monitore-os regularmente. Realize auditorias periódicas para avaliar o cumprimento das práticas de TPM e promova uma cultura de melhoria contínua. Envolva a equipe em treinamentos e reconhe?a os esfor?os para manter o engajamento. Além disso, crie planos de a??o para tratar desvios e assegure a comunica??o entre todos os níveis da organiza??o. Evite retrocessos refor?ando a disciplina nas rotinas e revisando os processos periodicamente, adaptando-se às mudan?as operacionais para evitar complacência.

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Kasim S

SAP PPQM PPDS / IBP / Scrum Certified consultant
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TPM, I learned during my tenure in TVS MOTORS COMPANY LIMITED, JH level of initial cleaning, deducting the wastage and eliminating the wastages. Avoid over production. Try with Limited resource. Make team with 100% contribution etc. Such a nice journey of learning TPM concepts.

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Túlio Martins

Te ajudo a implementar TPM, melhorar processos e aumentar a eficiência operacional | Consultor Sênior | TPM, WCM, Lean Manufacturing e Melhoria Contínua
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Estabele?a a política e vis?o do TPM com o comprometimento da alta dire??o, definindo objetivos claros alinhados às metas estratégicas da empresa. A vis?o deve focar em maximizar a eficiência dos ativos, com ênfase na melhoria contínua, seguran?a e engajamento de todos os colaboradores, sendo comunicada de forma clara e consistente.

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2 Implement a TPM audit system

The second step to sustain and audit the results of TPM is to implement a TPM audit system that monitors and evaluates the performance and progress of your TPM program. A TPM audit system should include both internal and external audits, as well as self-assessments and peer reviews. The audits should cover all the aspects of TPM, such as the 5S, autonomous maintenance, planned maintenance, quality maintenance, focused improvement, education and training, safety and environment, and TPM in administration. The audits should also use objective and measurable criteria, such as key performance indicators (KPIs), checklists, and scorecards, to assess the level of TPM implementation and maturity in your organization.

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Jai Balachandran

Founder - MaintWiz CMMS | Asset Management | Plant Maintenance | TPM Digitalization | OEE | OT-IT Integration | industry 4.0 | SaaS Innovator
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Implementing a robust TPM audit system is essential for sustaining. 1. Define Objectives: Clearly establish measurable goals related to TPM every year. 2. Audit Process: Set a regular audit schedule with standardized checklists to consistently evaluate all TPM activities. 3. Technology: Tools like CMMS is invaluable for adhering to TPM processes, tracking audit results, managing KPIs, and implementing corrective actions. Data driven oversights prevent backsliding. 4. Engage Teams: Involve cross-functional teams to ensure ownership, engagement and accountability. 5. Continuous Improvement: Use audit insights to address gaps and improve. A well-executed TPM audit system, ensures continuous improvement and prevents complacency.

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Túlio Martins

Te ajudo a implementar TPM, melhorar processos e aumentar a eficiência operacional | Consultor Sênior | TPM, WCM, Lean Manufacturing e Melhoria Contínua
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Para implementar um sistema de auditoria de TPM, comece definindo critérios claros para cada pilar, com indicadores mensuráveis e processos padronizados. Crie uma equipe de auditores capacitados, realize auditorias periódicas e use os resultados para ajustes contínuos, garantindo a evolu??o do TPM e evitando desvios.

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3 Celebrate and reward TPM achievements

The third step to sustain and audit the results of TPM is to celebrate and reward the achievements and improvements of your TPM program. This can help to motivate and engage your employees, as well as to recognize and appreciate their efforts and contributions. You can celebrate and reward TPM achievements in various ways, such as by announcing and sharing the results of your TPM audits, by organizing recognition ceremonies and events, by giving feedback and praise, by providing incentives and bonuses, or by creating a culture of learning and innovation.

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Túlio Martins

Te ajudo a implementar TPM, melhorar processos e aumentar a eficiência operacional | Consultor Sênior | TPM, WCM, Lean Manufacturing e Melhoria Contínua
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Celebre as conquistas do TPM com eventos de reconhecimento, recompensas financeiras, ou prêmios simbólicos para equipes e indivíduos que se destacam. Publicar os resultados em murais ou comunicados internos e criar uma cultura de reconhecimento contínuo também refor?a o compromisso com o TPM e motiva a equipe.

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4 Identify and address gaps and challenges

The fourth step to sustain and audit the results of TPM is to identify and address the gaps and challenges that may hinder or limit your TPM program. These can include technical, organizational, or cultural issues, such as lack of skills, resources, or support, resistance to change, poor communication, or low morale. You should analyze the root causes of these gaps and challenges, and develop action plans to overcome them. You should also involve your employees in the problem-solving process, and empower them to take ownership and responsibility for the improvement of their own work areas and processes.

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Jai Balachandran

Founder - MaintWiz CMMS | Asset Management | Plant Maintenance | TPM Digitalization | OEE | OT-IT Integration | industry 4.0 | SaaS Innovator
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Iand addressing gaps and challenges is pivotal for maintaining effectiveness of TPM. 1. Regular Gap Analysis: Periodically assess discrepancies between current practices and TPM standards. 2. Leverage Technology: Use technology systems to digitalize process assests and provide data-driven insights. 3. Open Communication: Encourage ongoing feedback across all staff levels to uncover less apparent issues. 4. Corrective Actions: Quickly address identified issues to prevent them from escalating. Regularly tackling these aspects ensures continuous TPM improvement and operational excellence.

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Túlio Martins

Te ajudo a implementar TPM, melhorar processos e aumentar a eficiência operacional | Consultor Sênior | TPM, WCM, Lean Manufacturing e Melhoria Contínua
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Identifique lacunas do TPM por meio de auditorias regulares, análise de KPIs e feedback dos operadores, buscando áreas de baixa performance ou desvios nos processos. Resolva esses desafios com treinamentos direcionados, ajustes no plano de a??o e acompanhamento contínuo, sempre promovendo a melhoria contínua e o engajamento das equipes.

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5 Continuously improve and innovate

The fifth step to sustain and audit the results of TPM is to continuously improve and innovate your TPM program. This means that you should not settle for the status quo, but always look for opportunities to enhance and optimize your equipment and processes. You should also encourage your employees to generate and implement new ideas and solutions, and to experiment and learn from failures. You should also benchmark your TPM performance against the best practices and standards in your industry, and adopt new technologies and methods that can help you achieve higher levels of excellence.

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Túlio Martins

Te ajudo a implementar TPM, melhorar processos e aumentar a eficiência operacional | Consultor Sênior | TPM, WCM, Lean Manufacturing e Melhoria Contínua
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Melhore continuamente revisando os processos, analisando dados e implementando feedback das equipes para identificar oportunidades de inova??o. Promova o uso de novas tecnologias, incentive a troca de ideias entre colaboradores e aplique metodologias de melhoria contínua, como Kaizen, para manter a evolu??o constante no TPM.

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6 Review and revise your TPM program

The sixth and final step to sustain and audit the results of TPM is to review and revise your TPM program periodically. This means that you should evaluate the effectiveness and efficiency of your TPM program, based on the data and feedback from your TPM audits and activities. You should also identify the strengths and weaknesses of your TPM program, as well as the opportunities and threats that may affect it. You should then adjust and update your TPM policy and vision, your TPM audit system, your TPM achievements and rewards, your TPM gaps and challenges, and your TPM improvement and innovation, accordingly.

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Jai Balachandran

Founder - MaintWiz CMMS | Asset Management | Plant Maintenance | TPM Digitalization | OEE | OT-IT Integration | industry 4.0 | SaaS Innovator
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Reviewing TPM program is crucial for sustaining its effectiveness. 1. Regular Reviews: Establish periodic reviews of your TPM program against business goals. Address gaps. 2. Metrics: Use performance metrics and feedback to assess the program’s effectiveness - success and failures. 3. Learnings: Integrate new insights and industry practices into your TPM program. 4. Communications: Clearly communicate any changes in your TPM strategy to all stakeholders for alignment. Regularly revising your TPM program based on systematic reviews and data-driven insights ensures that your maintenance practices remain robust and responsive to changing operational needs.

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Túlio Martins

Te ajudo a implementar TPM, melhorar processos e aumentar a eficiência operacional | Consultor Sênior | TPM, WCM, Lean Manufacturing e Melhoria Contínua
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Revise o programa de TPM periodicamente por meio de auditorias, análise de KPIs e reuni?es de acompanhamento com as equipes. Avalie o progresso em cada pilar, identifique áreas de melhoria e ajuste as estratégias conforme necessário para garantir a sustentabilidade e a evolu??o do programa.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Paulo Canario

JIPM TPM Instructor #167 Sócio-gerente Fact Consulting
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Todos os tópicos relacionados no artigo se sustentam se as atividades de TPM estiverem totalmente integradas com a Gest?o da Rotina. Esse é o elemento vencedor e que sustentará as práticas vivas. Os resultados ser?o consequência!

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Asanka Chathuranga MBA, BSc.(Eng.), CLSSBB

IWS(RTT) Expert | Breakthrough results in 04 manufacturing pilot sites, 09 global deployments in 2+ years | Bottom-line savings $1.4 million, 58 Lean Six Sigma projects | Continuous Improvement| WCM | TPM | Quality
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To enhance TPM or pillar governance, I propose forming a dedicated TPM core team or promotional organization. This team, composed of subject matter experts for each daily management system, will be key to our success. Regular bi-weekly reviews of the team charter and master plan, including DMS health checks, performance reviews, and activity planning, will ensure sustained results. Furthermore, fostering coordination among the Org, ENT, PM, AM, and LDR pillars, along with continuous training, is essential to maintaining a robust skill pool and driving our initiatives forward.

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Jai Balachandran

Founder - MaintWiz CMMS | Asset Management | Plant Maintenance | TPM Digitalization | OEE | OT-IT Integration | industry 4.0 | SaaS Innovator
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Sustaining a thriving TPM program requires a holistic approach that goes beyond the initial implementation: ? Leadership Commitment: Executive buy-in is crucial. Leaders who actively champion TPM principles ensure long-term program success. ? Cultural Shift: TPM fosters a culture of ownership and accountability. Invest in employee training and communication to create a continuous improvement culture. ? Staying Ahead: Manufacturing is constantly evolving. Digitalize. Embrace Industry 4.0 technologies. Use data analytics with TPM practices to maintain a competitive edge. ? Integration: Ensure seamless integration of your TPM program with other enterprise initiatives and systems.

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Rishi Kumar

JIPM certified TPM Instructor: Consultant, Corporate Trainer, Speaker
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Every Organization is unique in some ways. Any attempt to copy paste the TPM Implementation is a risky recipe, with high probability of failure. Just take the case of Audits, if you borrow the Audit sheets from a company which has implemented TPM and start conducting audits in your Plant using those audit sheets, what is likely to happen? You will be missing out on some of the key improvement areas. Your checklist needs some degree of customization. It is important to adopt and adapt. Be a keen learner, understand the ground reality through TPM diagnosis. Design the TPM implementation approach accordingly. That subtle unique combination of people, practices and systems is a differentiator, and locks the gains to sustains success

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How do you sustain and audit the results of TPM and avoid backsliding or complacency?

1

2

3

4

5

6

7

1 Establish a TPM policy and vision

2 Implement a TPM audit system

3 Celebrate and reward TPM achievements

4 Identify and address gaps and challenges

5 Continuously improve and innovate

6 Review and revise your TPM program

7 Here’s what else to consider

Total Productive Maintenance (TPM)

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