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What are the top TPM strategies for improving equipment maintenance?

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Equipment maintenance is a crucial factor for manufacturing success, as it affects productivity, quality, safety, and costs. However, traditional maintenance approaches, such as reactive or preventive maintenance, may not be enough to cope with the increasing complexity and variability of modern equipment. That's why many manufacturers adopt total productive maintenance (TPM) as a strategic way to improve their equipment performance and reliability. TPM is a holistic and proactive method that involves everyone in the organization, from top management to shop floor workers, in maintaining and improving the equipment. In this article, we will explore some of the top TPM strategies for improving equipment maintenance and how to implement them effectively.

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Seraiah Chatfield

Infrastructure Lead - System Administrator A+ Net+ Sec + ITIL 4 Cyber Security Enthusiast
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 Define and measure OEE

One of the key concepts of TPM is overall equipment effectiveness (OEE), which is a metric that measures how well the equipment is performing in terms of availability, performance, and quality. OEE is calculated by multiplying these three factors, and the result is expressed as a percentage. The higher the OEE, the more productive and efficient the equipment is. To improve equipment maintenance, you need to define and measure OEE for each equipment or process, and identify the causes of low OEE. These causes are known as the six big losses: breakdowns, setup and adjustment, idling and minor stops, reduced speed, defects and rework, and startup losses. By tracking and analyzing OEE and the six big losses, you can prioritize the most critical issues and plan your maintenance actions accordingly.

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Gramapurohit Jayathertha

Driving Digital Transformation | Partner Manager- APAC Region |Siemens Industry Software | Partnerships & Growth with Innovation & Impactful solutions. @ Siemens Industry Software | Software Partnering for growth|
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OEE is important indicator but it’s only a tip of the iceberg. OEE is merely an indication for optimisation. There will be lack of information from real time running machines and missing transparency due to paper based manufacturing information. Product optimisation with real time date from the machine is key for the technological optimisation, shop floor optimisation and cross process KPI and evaluation. This need deep integration with machine tools through digital transformation technologies. This will also help in predictive maintenance. You can monitor mechanical properties of the assets also. Go for non sensor IOT solutions. Helps in conditional monitoring together with OEE

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2 Implement autonomous maintenance

Another important strategy of TPM is autonomous maintenance, which means empowering the operators to perform basic maintenance tasks on their own equipment, such as cleaning, inspecting, lubricating, tightening, and adjusting. Autonomous maintenance helps to prevent equipment deterioration, detect abnormalities, and improve operator skills and ownership. To implement autonomous maintenance, you need to follow a seven-step process that starts with initial cleaning and inspection, and ends with standardization and continuous improvement. You also need to provide adequate training, tools, and support to the operators, and encourage them to share their knowledge and suggestions.

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Seraiah Chatfield

Infrastructure Lead - System Administrator A+ Net+ Sec + ITIL 4 Cyber Security Enthusiast
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Giving the operators the freedom to maintain their own equipment empowers them to truly own the machine. Additionally instilling pride of ownership can be advantageous. The operator should also share in the rewards of a properly running and efficient machine center. Its important that the operator is trained in proper maintenance (also a pillar of TPM).

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3 Conduct planned maintenance

Planned maintenance is the opposite of reactive maintenance, which means waiting for the equipment to fail and then fixing it. Planned maintenance is a proactive approach that involves scheduling and performing maintenance activities based on the equipment condition, performance, and usage. Planned maintenance helps to prevent breakdowns, extend equipment life, reduce maintenance costs, and optimize spare parts inventory. To conduct planned maintenance, you need to collect and analyze data on the equipment history, condition, and failure modes, and use it to determine the optimal maintenance frequency, type, and method. You also need to coordinate with the production team, the maintenance team, and the suppliers to ensure smooth execution and minimal disruption.

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4 Apply focused improvement

Focused improvement is a strategy that aims to eliminate chronic losses and problems that affect the equipment performance and reliability. Focused improvement is based on the principle of continuous improvement, which means constantly looking for ways to reduce waste, improve quality, and increase efficiency. To apply focused improvement, you need to form cross-functional teams that work on specific improvement projects, using tools and techniques such as root cause analysis, brainstorming, 5S, Kaizen, and PDCA. You also need to monitor and evaluate the results of the improvement actions, and standardize and sustain the best practices.

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5 Develop skilled workers

Skilled workers are essential for effective equipment maintenance, as they can operate, maintain, troubleshoot, and improve the equipment with confidence and competence. Developing skilled workers is a strategy that involves providing regular training, coaching, and feedback to the workers, and creating a culture of learning and collaboration. To develop skilled workers, you need to assess the current skill level and gap of the workers, and design a training program that covers both technical and soft skills. You also need to create opportunities for the workers to practice, apply, and share their skills, and recognize and reward their achievements.

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6 Engage top management

Top management engagement is a critical factor for the success of TPM, as it provides the vision, direction, and support for the equipment maintenance improvement. Engaging top management is a strategy that involves communicating the benefits and challenges of TPM, setting clear and realistic goals and expectations, allocating adequate resources and budget, and promoting a culture of teamwork and accountability. To engage top management, you need to present them with data and evidence on the current and potential OEE and the six big losses, and show them how TPM can improve the bottom line and customer satisfaction. You also need to involve them in the planning, implementation, and review of the TPM activities, and report on the progress and results regularly.

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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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The beauty of TPM is seen when it is linked with the operational strategy. The best of TPM is gained when it stems from the leadership. I was fortunate to lead and drive some significant deep cleaning activities in Vietnam, Malaysia and Sri Lanka where General Managers were involved and did the cleaning the machine by themselves to show the servant leadership. That will boost the morale and positive attitude for the people to embrace the TPM culture, system and thus improve performance. Leaders should demonstrate how it is done, then it's a matter of following up by the team around you.

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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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What are the top TPM strategies for improving equipment maintenance?

1

2

3

4

5

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1 Define and measure OEE

2 Implement autonomous maintenance

3 Conduct planned maintenance

4 Apply focused improvement

5 Develop skilled workers

6 Engage top management

7 Here’s what else to consider

Manufacturing

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What are the top TPM strategies for improving equipment maintenance?

1

2

3

4

5

6

7

1 Define and measure OEE

2 Implement autonomous maintenance

3 Conduct planned maintenance

4 Apply focused improvement

5 Develop skilled workers

6 Engage top management

7 Here’s what else to consider

Manufacturing

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