23 Jun Total Productive Maintenance
TPM is composed by the first English letters of Total Productive Maintenance. Nakajima (1988), had given the original approach of TPM, defined it as the productive maintenance carried out by all employees through small group activities and can be viewed as equipment maintenance performed on a company-wide basis.
As a consequence, from the elimination of breakdowns and defects, the equipment operation rates improve, costs are reduced, inventory can be minimized and labor productivity increases (Nakajima, 1988). TPM brings maintenance into focus as a necessary and vitally important part of the business. TPM seeks engagement from intra and inter-department in an organization to maximize the overall effectiveness of production equipment. It involves production and maintenance staff working together as a team to reduce wastage, minimize downtime toward improving the end-product quality (Eti et al., 2004).
Other TPM definition was as follows:
- Target to achieve the maximum equipment efficiency (overall efficiency).
- Establish TPM system which targets at equipment life of maintenance prevention, preventive maintenance and corrective maintenance.
- All related persons should participate jointly, e.g. equipment planner (Planning Department), equipment user (Manufacturing Department), and maintenance person (Maintenance Department), etc.
- Promote TPM by independent small group activities.
It has four steps:
- Preparatory stage of importing TPM
- Commencement of importing TPM
- Implementation stage of importing TPM
- Realization stage (Shen, 2015).
Total Productive Maintenance (TPM) methodology is a proven and successful procedure for introducing maintenance considerations into organizational activities (Graisa and Al-Habaibeh, 2010; Ahuja and Khamba, 2008; Ahmed et al., 2004; Blanchard, 1997; Hartman, 1992). It involves operational and maintenance staff working together as a team to reduce wastage, minimize downtime and improve end product quality (Eti et al., 2004; Bakri, 2012).
The aim of TPM is to improve machines’ effectiveness by: early equipment management and maintenance prevention, shifting the routine activities of machinery operation and maintenance for their operators (Kariuki, 2013), increase the engagement of employees’ participation in those processes (Helman, 2012; Nakajima, 1988)
When failures and defects are eliminated, the rate of operating speed of machines will rise, operating costs will be reduced and productivity will increase (Brzeski, 2006; Nakajima, 1988; Chlebus, 2015)
It generally takes 2.5 to 3 years for an enterprise to implement total productive maintenance (TPM) in a full swing; however, the actual duration depends on each company’s corporate status. Generally speaking, for a company with big staff, it even takes 3 to 5 years, but the major consideration should depend on whether the actual benefit is remarkable or not (Shen, 2015).
- Ahmed, S., Hassan, M., Taha, Z. (2004). “State of implementation of TPM in SMIs: a survey study in Malaysia”. Journal of Quality in Maintenance Engineering, Vol.10 No.2, pp. 93-106.
- Ahuja I. P. S., Khamba, J. S. (2008). “Total productive maintenance: Literature review and directions”. International Journal of Quality and Reliability Management, Vol.25 No.7, pp. 709-756.
- Bakri, A., Abdul Rahim, A. R., Yusof, N. M., Ahmad, R. (2012). “Boosting Lean Production via TPM”. Procedia – Social and Behavioral Sciences, 65, 485 – 491.
- Blanchard, B. S. (1997). “An enhanced approach for implementing total productive maintenance in the manufacturing environment”. Journal of Quality in Maintenance Engineering, Vol.3 No.2, pp. 69-80.
- Brzeski, J., Figas, M. (2006). “Prowadzenie do TPM”. Inżynieria i utrzymanie ruchu zakładów przemysłowych.
- Chlebus, E., Helman, J., Olejarczyk, M., Rosienkiewicz, M. (2015). “A new approach on implementing TPM in a mine – A case study”. Archives of civil and mechanical engineering, 15, 873-884.
- Eti, M.C., Ogaji, S. O. T., Robert, S. D. (2004). “Implementing total productive maintenance in Nigerian manufacturing industries”. Applied Energy, Vol 79, pp 385-401.
- Graisa,M., Al-Habaibeh, A. (2010). “An investigation into current production challenges facing the Libyan cement industry and the need for innovative total productive maintenance (TPM) strategy”. Journal of Manufacturing Technology Management, Vol. 22, No.4, pp.541-558.
- Hartmann, E. H. (1992). “Successfully Installing TPM in Non-Japanese Plant: Total Productive Maintenance”. TPM Press Inc., London.
- Helman, J. (2012). “Analysis of the potentials of adapting elements of Lean methodology to the unstable conditions in the mining industry”. AGH Journal of Mining and Geoengineering, 151.
- Kariuki, B. M. (2013). “Role of Lean manufacturing on organization competitiveness”. Industrial Engineering Letters, 3 (10), 86.
- Nakajima, S. (1988). “Introduction to TPM”. Productivity Press, Cambridge, MA.
- Shen, C. (2015). “Discussion on key successful factors of TPM in enterprises”. Journal of Applied Research and Technology, Volume 13, Issue 3, June 2015, Pages 425-427.