Total Productive Maintenance (TPM) is a methodology used to optimize equipment effectiveness and reduce breakdowns and losses through employee involvement and empowerment. TPM was introduced in Japan in the 1970s to help companies reduce costs, improve productivity and quality, and avoid waste. It involves all employees through techniques like autonomous maintenance and focuses on eliminating the eight major types of losses that inhibit productivity. TPM shares similarities with Total Quality Management in its emphasis on employee participation, documentation, and management commitment to drive continuous improvement.

1. TOTAL PRODUCTIVE
MAINTENANCE

2. INTRODUCTION
• Maintenance has a far greater impact on corporate
profitability than most managers are willing to consider,
much less admit .
• And, as the competitive environment in the world continues
to increase the pace, companies are looking for new
strategies to save on costs, develop employees to face future
challenges and bring about a new culture at work place.

3. WHAT IS TOTAL PRODUCTIVE
MAINTENANCE?
• TPM is a plant improvement methodology which enables
continuous and rapid improvement of the manufacturing
process through use of employee involvement, employee
empowerment, and closed-loop measurement of results.

4. WHY TPM?
TPM was introduced to achieve the following objectives.
The important ones are listed below.
• Avoid wastage in a quickly changing economic
environment.
• Producing goods without reducing product quality.
• Reduce cost.
• Produce a low batch quantity at the earliest possible time.

5. EVOLUTION OF TPM
• TPM descends from Japan and came into existence in the
seventies.
• After Dr W Edward Deming made an impact in Japan through
his teaching of quality, Japanese organization felt a need for
autonomous maintenance and small group activities to support
the quality movement.
• Today thousands of organizations all over the world are
implementing TPM and about 100organisations are now doing
it in India.

6. BENEFITS OF TOTAL PRODUCTIVE
MAINTENANCE (TPM)
• Productivity Improvement - Productivity is
improved through fewer losses in the company.
• Employee Ownership - Ownership of equipment by
operators throughAutonomous Maintenance.
• Increased Plant Reliability.
• Customer Satisfaction - TPM leads to high delivery
performance and customer satisfaction.

7. LOSSES OF TOTAL PRODUCTIVE
MAINTENANCE (TPM)
• Breakdown losses
• Setup and adjustment losses
• Idling and minor stoppage losses
• Speed losses
• Quality defects and rework losses
• Strat-up/ yield losses

8. EIGHT PILLARS OF TOTAL
PRODUCTIVE MAINTENANCE

9. SIMILARITIES AND DIFFERENCE
BETWEEN TQM AND TPM
• The TPM program closely resembles the popular Total
Quality Management (TQM) program. Many of the tools
such as employee empowerment, benchmarking,
documentation, etc. used in TQM are used to implement
and optimize TPM. Following are the similarities
between the two.
• Total commitment to the program by upper level
management is required in both programmers.

10. TYPES OF MAINTENANCE
1. Breakdown maintenance
2. Preventive maintenance (1951)
2a. Periodic maintenance (Time based maintenance -
TBM)
2b. Predictive maintenance
3. Corrective maintenance (1957)
4. Maintenance prevention (1960 )