TPM (Total Performance Management)

TPM (Total Performance Management)

TPM (Total Performance Management) is a global approach to equipment maintenance that strives to achieve perfect production:

  • ZERO Breakdowns
  • ZERO Small Stops or Slow Running
  • ZERO Defects
  • ZERO Accidents

TPM emphasizes proactive and preventative maintenance to maximize the operational efficiency of equipment. It blurs the distinction between the roles of production and maintenance by placing a strong emphasis on empowering operators to help maintain their equipment.


Autonomous Maintenance: Places responsibility for routine maintenance, such as cleaning, lubricating, and inspection, in the hands of operators

  • Gives operators greater “ownership” of their equipment.
  • Increases operators’ knowledge of their equipment.
  • Ensures equipment is well-cleaned and lubricated.
  • Identifies emergent issues before they become failures.
  • Frees maintenance personnel for higher-level tasks.

Planned Maintenance: Schedules maintenance tasks based on predicted and/or measured failure rates.

  • Significantly reduces instances of unplanned stop time.
  • Enables most maintenance to be planned for times when equipment is not scheduled for production.
  • Reduces inventory through better control of wear-prone and failure-prone parts.

Quality Maintenance: Design error detection and prevention into production processes. Apply Root Cause Analysis to eliminate recurring sources of quality defects.

  • Specifically targets quality issues with improvement projects focused on removing root sources of defects.
  • Reduces number of defects.
  • Reduces cost by catching defects early (it is expensive and unreliable to find defects through inspection).

Early Equipment Management: Directs practical knowledge and understanding of manufacturing equipment gained through TPM towards improving the design of new equipment.

  • New equipment reaches planned performance levels much faster due to fewer startup issues.
  • Maintenance is simpler and more robust due to practical review and employee involvement prior to installation.

Safety, Health, Environment: Maintain a safe and healthy working environment.

  • Eliminates potential health and safety risks, resulting in a safer workplace.
  • Specifically targets the goal of an accident-free workplace.


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