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Objective zero failure with the TPM method, Total Productive Maintenance

Do you want to reduce time and wasted resources? Produce more efficiently and reduce waste at a lower cost?

Choose the TPM method, Total Productive Maintenance, which improves the productivity of your equipment by reducing downtime and breakdowns. While optimising productivity, quality and other performance indicators.


Definition of the maintenance's technique : the TPM

The TPM method, Total Productive Maintenance, is a practice aimed at building a corporate culture that improves the efficiency of the production system. It allows the gradual transition from a curative maintenance system to preventive maintenance (or even predictive maintenance in some cases).

This is the result of a managerial focus on :

  • Establishing a Continuous Improvement Policy
  • Involving all staff by empowering them
  • Improving performance QUALITY / COSTS / DEADLINES
  • Improving equipment (productivity, efficiencies, etc.).
  • Total

    Considering all aspects of maintenance, involve everyone in it

  • Productive

    Ensuring maintenance by producing and penalising production as little as possible

  • Maintenance

    Maintainenance: repair, clean and grease. Spending time on this.

History of TPM, Total Productive Maintenance

TPM succeeded the American Preventive Maintenance (PM) and was developed in Japan after the Second World War.

TPM was introduced in the factories of the Nippondenso group before being formalised by the JIPM (Japan Institute of Plant Management).

In 1989, the JIPM defined 8 pillars on which a TPM approach is based to achieve a high level of industrial performance.

TPM is a registered trademark of JIPM.

What has changed in relation to PM is the participatory approach, the active participation of operators who know their machine (s) and therefore contribute effectively to its maintenance.


Purpose of the TPM approach, Total Productive Maintenance

The TPM approach, Total Productive Maintenance, focuses on the machine. It is increasingly becoming the first step in launching performance improvement initiatives.

To do this, the company must have eliminated the unexpected and chance in its production activities.

To be efficient, a site needs a reliable and available production tool.

The TPM, Total Productive Maintenance allows you to visualise easily and graphically the main indicators and the factors that influence their results. These graphs provide reports, based on TPM criteria, delivering customised analysis for projections of specific time or resources.

The purpose of data analysis is to determine the main causes of underperformance and to focus on progress actions on the causes that generate the largest gains in OEE, Overall Equipment Effectiveness.

TPM systems have three main objectives:

Minimise under-utilisation of equipment that causes large losses, including financial losses

Participate in the conservation of equipment through a real follow-up of maintenance

Improve the organisation and act on the factors that enable the best returns

Advantages in terms of direct results

  • Establishment of maintenance and cleanliness on workstations and their environment
  • Setting up a visual organisation
  • Eliminating waste of time and material
  • Improvement of equipment monitoring
  • General improvement of the environment

Behaviour benefits

  • Communicate and involve everyone
  • Reconsider your habits
  • Maintaining
  • Making sustainable the results achieved and progressing continuously
  • Respecting commitments and collective rules
  • Maintenance station with TPM

    The maintenance station is associated with each machine or manufacturing cell requiring immediate availability of tools for :

    • Meet preventive maintenance requirements
    • Reduction of space requirements
    • Optimisation of the working space and creation of a clean, tidy and rational space
  • TPM cleaning station

    This management technique offers a complete solution within the company, services and offices such as :

    • An increase in organisation and quality of work
    • An increase in productivity and efficiency
    • Accidents and technical breakdowns or malfunctions reduction
  • TPM visual communication support

    The management of anomalies is approved with the largest industrial groups which allow operators to :

    • Express yourself in real time and without constraint
    • Implementation is fast, efficient, simple and economical
    • To encourage better overall performance


    The TPM (Total Productive Maintenance) approach improves the production capacity of technical resources by building a system that avoids losses and waste such as "zero accidents, zero faults and zero breakdowns". This technique is based on fieldwork (Gemba) and concret (Genbutsu) throughout the life cycle of the production system.

    The TPM involves the participation of all divisions. Not only those related to production but also the conception of production, development, marketing and administrative services, at all hierarchical levels, from managers to operators.

    It enables to reach the "zero losses" by engaging in small group improvement initiatives.

    Everyone must find an advantage in the TPM approach and this is not always the financial aspect even if it is put forward. This argument sometimes masks deeper needs.

    One of the indeniable advantages for operators is that "it feels good to remove the thorn in your side".

    This thorn can be as well the routine that one perceives, the attitude of the hierarchy, the feeling of not being heard as the difficulties that one encounters to carry out its work in normal conditions (difficulties due to the material, the raw materials, the organisation). This thorn can also be the need to feel useful, to be able to solve the problems encountered.


    Average duration: 2h30

    On the principle of an automobile route journey presented in the form of the game of the Goose sown with hazards, one tries to eliminate all sources of dysfunction of the means of production (external and internal)

    Don't wait any longer to train your colleagues in TPM through games

    The TPM-PDCA-SUGGESTION Starter Kit: Simple development of a PDCA board, improvement proposals (suggestion) and TPM (Total Productive Maintenance) as part of a pilot project following the game.

    Results: collective and effective success.


    Sesa Systems creations for the TPM method

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