Total Productive Maintenance

A set of techniques, originally pioneered by Denso in the Toyota Group in Japan, to ensure that every machine in a production process always is able to perform its required tasks.

The approach is termed total in three senses. First, it requires the total participation of all employees, not only maintenance personnel but line managers, manufacturing engineers, quality experts, and operators. Second, it seeks total productivity of equipment by focusing on all of the six major losses that plague equipment: downtime, changeover time, minor stops, speed losses, scrap, and rework. Third, it addresses the total life cycle of equipment to revise maintenance practices, activities, and improvements in relation to where equipment is in its life cycle.

Unlike traditional preventive maintenance, which relies on maintenance personnel, TPM involves operators in routine maintenance, improvement projects, and simple repairs. For example, operators perform daily activities such as lubricating, cleaning, tightening, and inspecting equipment.