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

1. Implementing Total Productive Maintenance in
Manufacturing, Fabrication, Pharmaceutical, FMCG, Oil
field and other process Industries.
Top Management Consulting Firms in India
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

2. 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
1
Zero breakdown
2

3. Zero Accident
3
Zero Defects
Key pillars of TPM are
1
Focussed improvements
2
Autonomous Maintenance
3
Planned maintenance
4
Early Management
5
Quality Maintenance
6
Skill training
7
Administrative and supporting functions.
8
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.

4. Evaluating the effective implementation of TPM involves
1
Assessing whether the organization has achieved policy and goals set before the launching of TPM
2
Whether the company has realized the intended benefits
3
How effectively topics are prioritized, action plans and quantitative targets have been pursued through
continuous improvement activities.
4
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
1
Set up a promotion office – TPM promotion office
2
Launch TPM introductory education to every team member
3
Form small group
4
Select group leaders

5. 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 Corporate – Precision Engineering
Applied 5S
TPM
Lean Experimental Learning Programme