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What are the best TPM performance indicators for total productive maintenance?

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Total productive maintenance (TPM) is a strategy that aims to improve the reliability and efficiency of your manufacturing equipment and processes. By involving everyone in the organization, from operators to managers, TPM fosters a culture of continuous improvement and problem-solving. But how do you measure the success of your TPM efforts? What are the best TPM performance indicators that reflect your progress and performance? In this article, we will explore some of the most common and useful TPM metrics that can help you monitor and improve your total productive maintenance.

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1 OEE: Overall Equipment Effectiveness

One of the most widely used TPM performance indicators is OEE, which stands for overall equipment effectiveness. OEE measures how well your equipment is performing in terms of availability, performance, and quality. It is calculated by multiplying these three factors, which are expressed as percentages. OEE can help you identify the main sources of losses and inefficiencies in your equipment and processes, such as breakdowns, setup times, speed losses, defects, and rework. OEE can also help you benchmark your performance against industry standards and best practices.

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Scott Haulotte

Plant Manager accomplished in diverse manufacturing technologies and known for developing teams and best practices leading to profitable and sustainable margins.
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I completely agree that OEE is the best introductory KPI for measuring a TPM program. The key is to measure it the correct way. The Japanese Institute for Plant Maintenance (JIPM) outlines the formula. What I find is that many companies do not follow that standard and as a result are overstating their OEE. The machine availability rate should only exclude breaks and meetings assuming the machine is down for them. Many companies remove planned maintenance time because PM, PDM, etc are good things. They are not, they are a loss which prevents the machine from operating. These activities are better than a “run to failure” scenario but Preventive Maintenance work should be challenged to be efficient just as the production process is.

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Ali Raza Shahid BS. Mech (Hons), MBA, Boiler Engineer

Maintenance Section Head E&M
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The best TPM performance indicators for total productive maintenance include Overall Equipment Effectiveness (OEE), Mean Time Between Failures (MTBF), Mean Time to Repair (MTTR), Planned Maintenance Percentage (PMP), and Autonomous Maintenance (AM) completion rate. These indicators help assess equipment reliability, maintenance efficiency, and overall equipment performance. Monitoring these metrics allows for proactive maintenance practices, minimizing downtime, optimizing productivity, and enhancing overall equipment effectiveness in the long run.

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Wayne Skutt, MA

Curiosity takes us farther than ambition.
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For me OEE (Overall Equipment Effectiveness) is the best introductory KPI for measuring your TPM program. From there work through effective problem solving to gain a foothold in your culture change.

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Chuck H. Mograbi MS HONS

Engineering/Product Development/ MDR/Clinical Strategy - Regulatory Submission
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The best Productive Maintenance performance indicators include Overall Equipment Effectiveness (OEE), measuring performance, availability, and quality; Mean Time Between Failures (MTBF) for equipment reliability; Mean Time to Repair (MTTR) for maintenance efficiency; Planned Maintenance Percentage (PMP) to assess preventive maintenance; Equipment Downtime tracking total unavailable time; Maintenance Cost per Unit for cost-effectiveness; Schedule Compliance for planned activities; Maintenance Completion Rate reflecting operator engagement; Mean Time to Failure (MTTF) for reliability; and Changeover Time impacting productivity. These indicators help optimize maintenance, improve equipment effectiveness, and enhance overall productivity.

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2 MTBF: Mean Time Between Failures

Another important TPM performance indicator is MTBF, which stands for mean time between failures. MTBF measures the average time that your equipment operates without any interruptions or failures. It is calculated by dividing the total operating time by the number of failures. MTBF can help you evaluate the reliability and durability of your equipment and components, as well as the effectiveness of your preventive maintenance and repair activities. MTBF can also help you plan your maintenance schedules and spare parts inventory.

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3 MTTR: Mean Time To Repair

A related TPM performance indicator is MTTR, which stands for mean time to repair. MTTR measures the average time that it takes to restore your equipment to its normal operating condition after a failure. It is calculated by dividing the total downtime by the number of failures. MTTR can help you assess the responsiveness and efficiency of your maintenance and repair teams, as well as the availability and accessibility of your spare parts and tools. MTTR can also help you reduce your downtime and improve your availability.

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4 Six Big Losses

The six big losses are a more comprehensive set of TPM performance indicators, which identify the root causes of inefficiencies and wastes. These losses include breakdowns, setup and adjustment, idling and minor stoppages, reduced speed, process defects, and reduced yield. By measuring and analyzing these losses, you can implement improvement actions to eliminate or minimize them.

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5 TPM Scorecard

The TPM scorecard is a useful tool to track and communicate your TPM performance indicators. This visual dashboard shows your key TPM metrics and targets, helping you to align your goals with your business strategy and customer needs. It enables you to monitor and evaluate performance and progress over time, as well as identify and prioritize improvement opportunities. Additionally, the TPM scorecard can engage and motivate employees to contribute to your TPM efforts, and celebrate successes. When customizing a TPM scorecard, it should include a clear title that reflects the TPM vision, relevant and measurable performance indicators, a baseline and target for each indicator, a color-coded or graphical representation of performance versus target, and a summary or commentary highlighting strengths, weaknesses, opportunities, and challenges.

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Duilio Botelho

Gerente da Qualidade | Produ??o | Problem Solver | Excelência Operacional | Lean | WCM
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Um conjunto de KPIs direcionados a tomadas de decis?o rápidas, integradas com o planejamento de produ??o foca em evitar paradas de máquinas n?o programadas, consequentemente, trazer melhor eficiência a opera??o, assim garantindo a quantidade produzida com a qualidade desejada! Metas atingíveis devem ser criadas e constantemente "desafiadas" para promover melhora do processo e máquina, assim como o custo da opera??o envolvida.

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6 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 best TPM performance indicators for total productive maintenance?

1

2

3

4

5

6

1 OEE: Overall Equipment Effectiveness

2 MTBF: Mean Time Between Failures

3 MTTR: Mean Time To Repair

4 Six Big Losses

5 TPM Scorecard

6 Here’s what else to consider

Manufacturing

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What are the best TPM performance indicators for total productive maintenance?

1

2

3

4

5

6

1 OEE: Overall Equipment Effectiveness

2 MTBF: Mean Time Between Failures

3 MTTR: Mean Time To Repair

4 Six Big Losses

5 TPM Scorecard

6 Here’s what else to consider

Manufacturing

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