TPM was development in the 1970s as a method of involving machine operators in the preventive maintenance of their machine.

Autonomous maintenance activities knock the knowledge and skill of the people who work with the equipment on a daily basis .Involving machine operators also makes the regular maintenance people more productivity by focusing them on more extensive preventive maintenance task

Preventive maintenance is a schedule of planned maintenance actions aimed at the prevention of breakdowns and failures. The primary goal of preventive maintenance is to prevent the failure of equipment before it actually occurs. It is designed to preserve and enhance equipment reliability by replacing worn components before they actually fail.

 Increased Automation Business loss due to production delays

Production of a higher quality product

Just-in-time manufacturing Need for a more organized, planned environment

The objective of TPM is the elimination of Losses ,waste include equipment downtime, defects ,scrap, accidents , wasted energy, and labor inefficiency
.

Equipment reliability is a cornerstone of a lean production system

Safer Working Environment . Improved equipment Reliability Uptime Increased Capacity. Increased Productivity. Increased Quality. Company financial performance and job security will improve. Improved safety and quality conditions.

 The goal of TPM is to drive all waste to zero; Zero Accidents, Zero Defects ,Zero Breakdowns

The concept of Zero built upon error proofing activities, or Poka Yoke ,in design of the process to make it impossible to make and pass or defects .Poka- Yoke concept are also commonly applied to equipment to prevent breakdowns ( e.g. Automatic lubrication system )

The primary metric to gauge TPM performance is Overall Equipment Effectiveness or OEE OEE is a combined measurement that show the impact of equipment performance, and quality of output. The metric is calculated by multiplying (Availability x Performance x Quality)

Availability
100% minus the following: All known losses ( stoppages), measured in time , due to equipment failures. Losses ( in time) due to process set-up and adjustments, Losses ( in time ) due to start-ups after shift, breaks, lunch and weekends

Performance:
100% minus the following : Losses ( in time ) due to minor stoppages Losses ( in time ) due to speed ( Actual vs . Engineered speed )

Quality: 100% minus the following : Losses due to defect and rework
Example : so, if Availability is 95% Performance is 97%, and Quality is 98% then OEE is .95X.97 X .98 = 90.3%

There are five core element to a TPM program:

1. Operator Self Maintenance Basic program of cleaning ,lubrication ,general inspection and minor preventive maintenance to be completed production operator 2. Conduct planned maintenance Developed and execute planed maintenance activities. Establish standard for each piece of equipment's, prioritize equipment based on relative importance to safety, quality, productivity 7 cost .Established a maintenance plan for each piece of equipment based on time, condition ,overhaul, or predictive maintenance 3. Small Group Kaizen activities 4. Education & Training 5. Maintenance prevention- Early equipment management is a system whereby shop-floor personal participate in the new equipment concept & design phase to develop equipment that require less maintenance , and is more easily maintained when maintenance required .

 Education & Training Support & Guidance for Operator Self Maintenance Provide instructions to operators on cleaning ,lubrication, safety, and contamination countermeasures. Support Kaizen activities. Downtime Countermeasure- Track breakdown, analyze root cause ,apply countermeasures. The goal is to increase mean time between failure and reduce mean time to repair. Preventive Maintenance Program Identify and number all equipment, established standards for cleaning, lubrication program activities. Spare Parts Management Established inventory standards and record points for parts needed on planned basis. Apply 5S principles to storage Area. Maintenance Cost Analysis Understand where cost is incurred for parts, indirect supplies, oil & lubricants, manpower and outsides contractors. Organize systematic actions to reduce cost goal is to reduce long term total cost- not to be sacrificed for short term cost improvement. Maintenance Efficiency Improvement Track maintenance activities by category: planned ( time-based, condition based, predictive ), and unplanned ( breakdown ) .Goal is to increase percentages of maintenance hours on planned vs unplanned, and lower overall total for both.