In industry, total productive maintenance (TPM) is a system of

maintaining and improving the integrity of production and quality

systems through the machines, equipment, processes, and employees
that add business value to an organization
The term total productive maintenance is attributed to Nippon Denso
in 70’s, it is a company that created parts for Toyota. However, Seiichi
Nakajima is regarded as the father of TPM because of his numerous
contributions to TPM
 TPM: Establishing a Corporate Culture
that will maximize production system effectiveness

Customer Satisfaction Over Global Competition

Quality
Productivity

Cost
CHANGING
Morale
CULTURE

Delivery
Safety

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TPM RESULTS
 The 8 Pillars of TPM
FOCUSED MEASUREMENT OF LOSSES, PROBLEM SOLVING,
PI IMPROVEMENT RELIABILITY IMPROVEMENT, SMED.

PII AUTONOMOUS MAINTENANCE RESET BASE LEVEL, INSPECTION STANDARDS, 5S, SETTING
STANDARDS.

PLANNED DOWNTIME REDUCTION

PIII MAINTENANCE INITIALIZATION OF CONDITION BASED MAINTENANCE

TRAINING AND TECHNICAL SKILLS REQUIREMENTS KNOW- HOW

PIV SKILLS DEVELOPMENT
INITIAL PHASE CHECK OF SPECIFICATIONS TECHNICAL EVOLUTIONS
PV
MANAGEMENT
QUALITY REDUCTION OF DEFECTS OPERATING STANDARDS
PVI QUALITY IMPROVEMENT
MAINTENANCE
ADMINISTRATIVE WORK 5S IN OFFICES
PVII IMPROVEMENT
5S IN WAREHOUSES
IMPROVE EFFICIENCY OF ADMINISTRATIVE TASKS
SAFETY & MANAGEMENT FOR ZERO ACCIDENT
PVIII ENVIRONMENT AND ZERO POLLUTION
 Program Development Master Plan
(Example of The First 3 Years)

TPM Award
Preparation Implementation Expansion
6 Months 1 Year 6 Months 1 Year

Steps 1-7 Step 7 Steps 8-9 Steps 10-11

1. Top Management’s
declaration to 7-(3) Planned Maintenance
introduce TPM
7-(4) Training and Skills Development
2. Introduction Training
3. TPM Organization 8. (5) Initial Phase Management
9. (6)Quality Improvement
4. Target Setting
5. Master Plan 10. (7)Administrative Work
11.(8)Safety & Environment
6. TPM Kick Off
7-(1) OEE/Focused Improvement
7-(2) Autonomous Maintenance

12. Total application of TPM

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TPM -Total Productive Maintenance
The 8 Pillars of TPM (Part 1)
The traditional TPM model consists of a 5S’ as the
foundation and eight supporting Pillars of activities
towards World Class results.
 1st S’ Seiri (Sort)
To take out unnecessary items either sort, red tag or
throw them away

Necessary: Unnecessary:
Used for daily work Unsafe
Used periodically Defective
I am the source Obsolete or outdated
Unused
Extra or duplicate
TPM -Total Productive Maintenance
5’ S Red Tag
Red Tag Sample
5S Red Tags are used to
keep the process of change
going throughout the 5S
program while remaining
organized in the process.
These 5S Red Tags are
used for visual
management of a
workspace, clearly marking
items that need to be
moved creating workplace
organization.
 1st S’ Seiri (Sort)

Critical items for use should be kept nearby. Items that are not be
used should be Red Tagged.
Items sorted should be decided based on utility and not cost to
reduce the Search time.
 2nd S’ Seiton (Simplify)
To arrange necessary items in a proper order so that
they can be easily picked up for use

Consider:
• Visual aids are encouraged in for fast retrieval and minimize complexity.
• Labeling locations where necessary items are kept but not in use,
especially moveable items.
• Labeling drawers and notebooks to identify their contents.
 2nd S’ Seiton (Simplify)
Label & shadow board

5S Map to decide location

"Anyone should be
able to easily
understand proper
arrangement and
abnormalities."
 3rd S’ Seiso (Sweep)
To clean your workplace completely so that there is
no dust anywhere
 Tools for Seiso (Sweep)

5S’ Assignment Map

5S’ schedule
 4th S’ Seiketsu (Standardize)
To maintain a high standard of housekeeping and
workplace organization at all times. Visual checks to
maintain the process.
5th S’ Shitsuke (Self Discipline)
To train people to follow good housekeeping
discipline independently