Total Productive Maintenance

The Purpose of Total Productive Maintenance (TPM) – to minimise operational disruption.

Breakdowns and process issues caused by equipment problems create operational disruption across the value chain.

TPM sets the  correct environment for the ownership of maintenance activities between operations and maintenance.

TPM is an asset care maintenance system designed to optimise and improve equipment effectiveness, extend asset life and reduce maintenance costs.

geneo-lean-operating-model-tpm spanner

TPM is a mechanism for detecting emerging problems with assets before they impact upon the bottom line.  It helps maintain and improve equipment standards to deliver optimum performance at the lowest possible cost. 

Maintenance of benchmark standards relating to plant and equipment reliability is pivotal providing dependable operational performance. A good Total Productive Maintenance strategy takes an end to end stance – from conceptual process and equipment design, through operations, to planning for new replacement facilities to secure future production requirements.   


Benefits of Total Productive Maintenance (TPM)

Total Productive Maintenance, when implemented fully, provides the following benefits:

  • Improvement in achievement of operational objectives and goals. 
  • All staff engaged and aligned in improvement activity.
  • Improved equipment performance over time, increasing availability of assets to produce best quality product

Role of a leader in Total Productive Maintenance

TPM provides an opportunity for all employees to participate in maintenance of plant and equipment. Leaders are therefore key to the deployment of the methodology.  

  • Maintain the adherence to current standards.  Perform process confirmation of tasks to ensure the baseline for all standards is accurate and the tasks are performed effectively.
  • Support the improvement of maintenance standards with the removal of waste to improve value add.
  • Ensure capability is built into the teams to successfully deploy the pillars of TPM.

TPM – Process

TPM consists of five Pillars that apply to all assets. For these to be successful they require effective standards to be in place for the execution of the maintenance task at hand.

geneo-lean-operating-model-tpm model

The 5 Pillars of Total Productive Maintenance: 

TPM provides a platform for operational stability and the aim to generate excess capacity.  This can only be achieved when standardised maintenance schedules are completed by Artisans and Operators providing dependable performance and continuous improvement based on shared experience and learning.

Overall Equipment Effectiveness

Autonomous Maintenance

Planned / Preventive Maintenance

Effective Training

Early Equipment Management


These Operational Excellence pages talk about fundamental lean principles and associated tools. Understanding how to apply these principles and tools to the individual circumstance of discrete organisations is where expertise and experience is paramount. The GENEO team has many decades of experience in doing exactly this.

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