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Implementing Total Productive Maintenance in Manufacturing, Fabrication, Pharmaceutical, FMCG, Oil field and other process Industries.

By 11th March 2020 No Comments
TPM Implementation & Benefits

Total Productive Maintenance is well known in its abbreviated form – TPM has origins from Japan.  It is a well structured and scientific method refined with many iterations for getting best and sustainable results. 

TPM is not only for machine intensive organisation. The approach and methodologies can be applied in the office environment also. 

When TPM methodology is implemented in an organisation, it helps in improving overall performance of business by

Improving teamwork among the entire organization members – top management to the front line.

Making machines function with high reliability and consistent performance.

Improving machine availability through reduction of down time and elimination of major losses which are defined elaborately according to TPM definitions.

Increased morale of the team members or front line members

Empowering and formally authorizing operators through TPM training and support to own and take pride in maintaining their own machines/ Equipment.

TPM is adopted company-wide and compliments many other parallel programmes on Operational Excellence such as Lean Manufacturing, Total Quality Management, Theory of constraints, Six Sigma.  TPM is characteristically applied to equipment with emphasis on input and causes. TPM emphasizes realization of ideal conditions to achieve the goal of Zero BAD which is total elimination of Breakdowns, Accidents and Defects.

TPM has a very meaningful definition and philosophy which has expansion for each letter as follows:

T stands for Total which includes

Total involvement of members from top management to frontline members.

Total Elimination of losses, breakdowns, accidents, and defects

P Stands for Productive which means

The overall pursuit of improving production efficiency.. productivity or effectiveness

M stands for Maintenance which means

Maintaining the best performance of the equipment by ensuring the right conditions that are needed to get the best performance over its intended life span and beyond.

Key characteristics of TPM

TPM methodology is designed to achieve overall improvements in plants that are beyond machinery.

Jishu Hozen – JH or Autonomous Maintenance - AM which is a key differentiator from traditional Preventive maintenance PM is that operators or the frontline members take ownership of operations and basic maintenance of the equipment.

Equipment Management in the modern era began with Preventive Maintenance and improved further into productive maintenance.  This originated in the United states as PM and had a high focus on the maintenance department.

TPM is also called as productive maintenance with total participation involving every level and every function of the organization has helped Japanese companies to be in the top of world in productivity, quality and cost advantages

Related Article– How To Customise TPM Implementation To Suit Your Organization Culture

The ultimate goal of TPM is Zero BAD


Zero breakdown

Zero Accident

Zero Defects

Key pillars of TPM are


Focussed improvements

Autonomous Maintenance

Planned maintenance

Early Management

Quality Maintenance

Skill training

Administrative and supporting functions.

Safety, Health, and Environment.

TPM helps in improving business results dramatically and enables safe, pleasant and productive workplaces by optimizing and improving teamwork between people working in different functions and roles.  TPM is also widely used in specialized process industries for achieving cost effective operations where equipment reliability and need to operate for long hours without stoppage is important. In such areas, even a minor stoppage or breakdown of one single piece of equipment or component can result in plant shutdown.

Major credit for formulating and documenting the structured implementation of TPM goes to Japan Institute of Plant Maintenance – JIPM.  Knowledge and implementation experience of other methodologies such as Lean, TQM, Six Sigma, Lean Six Sigma can complement implementation of TPM more effectively.

Evaluating the effective implementation of TPM involves


Assessing whether the organization has achieved policy and goals set before the launching of TPM

Whether the company has realized the intended benefits

How effectively topics are prioritized, action plans and quantitative targets have been pursued through continuous improvement activities.

Tangible benefits and intangible benefits realized.

Related Article– How operational excellence through TPM, Lean, TQM, TOC and 5S help organisations improve performance? – Case Studies & Success Stories

Intangible benefits of implementing any programme such as TPM, Lean, TOC, TQM or Lean Six Sigma should be considered important, It should be at least acknowledged.

Some of the intangible benefits of TPM are

Creating of safe working environment

Relaxed and meaningful workplace

Improved morale of people

Brand image and good will

Some of the initial steps of implementation of Structured TPM are


Set up a promotion office – TPM promotion office

Launch TPM introductory education to every team member

Form small group

Select group leaders

Related Article– Can we use best practices as combination of Lean, TPM, TQM, Kaizen, Six Sigma?

After this, each group needs to understand its present position and circumstances – as is the situation, identify the problems faced by its part of the organisation , determine the ideal condition to aim for and opportunities available. With this, aim to set up consensus and aligning team thinking.

Even though TPM can be implemented with inhouse resources, it has always worked by taking help of experienced and reliable consultants of TPM from Industry.  TPM consultants from Seven Steps are veterans in their industry and have working and consulting knowledge of over 20 – 30 years each and combined experience of over 200 years.

Seven Steps Business Transformation Systems – SSBTS is Consulting company of Seven Steps Group.  We have various specialities and have dedicated consultants for 

  • TPM Consulting
  • Lean Consulting for manufacturing,
  • Lean consulting for services
  • Lean consulting for hospitals
  • Lean consulting for retail
  • Lean consulting for supply chain and logistics
  • Lean consulting for construction

Where hands on implementation support is needed, it is supported by Seven Steps Business transformation system which is a consulting company specialized in implementation of Lean manufacturing, Total productive Maintenance, Theory of Constraints, Six Sigma.

Our customers have got significant benefits in saving of Cost of poor quality apart from gaining increased market shared, reduced logistics/air shipment costs.

Some of the flagship training programmes conducted at Seven Steps Academy of Excellence are:

Six sigma Green Belt

Six Sigma Black Belt

Six Sigma Yellow Belt

Skill development programme – Campus to CorporatePrecision Engineering

Applied 5S


Lean Experimental Learning Programme

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