TPM - Total Productive Maintenance



Total Productive Maintenance (TPM) is the lean methodology concerned with maximising the efficiency of Production Machinery. It’s more than just a maintenance programme or machine improvement activity. It’s a means for dramatically improving reliability by building the capabilities of people, processes, facilities and equipment.


TPM (Total Productive Maintenance) is a holistic approach to equipment maintenance that strives to achieve perfect production:

  • No Breakdowns
  • No Small Stops or Slow Running
  • No Defects

In addition it values a safe working environment:

  • No Accidents

TPM emphasises proactive and preventative maintenance to maximise 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.

The implementation of a TPM programme creates a shared responsibility for equipment that encourages greater involvement by production operators. In the right environment this can be very effective in improving productivity (increasing up time, reducing cycle times, and eliminating defects).

OEE Calculation

OEE (Overall Equipment Effectiveness) is a metric that identifies the percentage of planned production time that is truly productive. It was developed to support TPM initiatives by accurately tracking progress towards achieving 'Perfect Production'.

  • An OEE score of 100% is Perfect Production
  • An OEE score of 85% is world class for manufacturers
  • An OEE score of 60% is fairly typical for most manufacturers
  • An OEE score of 40% is not uncommon for manufacturers without TPM and/or a Continuous Improvement programme


TPM Goals

As can be seen from the table, OEE is linked to the TPM goals of No Breakdowns (measured by Availability), No Small Stops or Slow Running (measured by Performance), and No Defects (measured by Quality).


It is important to measure OEE in order to expose and quantify productivity losses, and in order to measure and track improvements resulting from TPM initiatives.


TPM focuses on getting managers, maintenance personnel and equipment users all working together to identifying and eliminating waste or loss associated with production equipment. By giving ownership and responsibility of equipment and processes to the right employees, equipment breakdowns and stoppages can be reduced.

TPM provides a systematic proactive approach to setting standards and visual guides for preventing breakdowns and making your equipment run smoothly.

TPM is integral to any Lean Production system, and is part of the foundation of operational stability.


This one day TPM workshop utilises practical examples to demonstrate the improvements that the successful implementation of a TPM programme can make to a business, and is ideally suited to personnel from Production, Maintenance, Engineering and Quality.

BTA can incoporate a post course assignment approach following this training to facilitate, coach and support the team in the application of TPM.

Check upcoming Lean Training events for dates and venues or contact us for further details