Total Productive Maintenance 141

Total Productive Maintenance introduces users to TPM concepts and principles. This class provides an overview of each key TPM pillar, including autonomous maintenance, Five S, planned maintenance, quality maintenance, kaizen, training, safety, and office TPM.

TPM combines aspects from lean manufacturing and quality initiatives to create a blended maintenance approach for both production and administrative areas. Improved safety, longer machine life, and increased employee involvement are just a few benefits of a well-executed TPM strategy. After taking this course, users will be able to describe the key components of total productive maintenance and their role in continuous improvement.

  • Difficulty Beginner

  • Format Online

  • Number of Lessons 17

  • Language English


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Course Outline
  • What is Total Productive Maintenance?
  • Lean and Quality
  • Types of Maintenance
  • Six Big Losses
  • Overall Equipment Effectiveness
  • TPM Review
  • Principles of TPM
  • Autonomous Maintenance
  • Five S
  • Planned Maintenance
  • Quality Maintenance
  • TPM Terms Review
  • Kaizen
  • Training
  • Safety
  • Office TPM
  • Final Review
  • Define total productive maintenance.
  • Describe lean manufacturing and quality.
  • Describe how TPM is connected to other types of maintenance approaches.
  • List the six big losses.
  • Define overall equipment effectiveness.
  • Identify the principles of TPM.
  • Define autonomous maintenance.
  • List the activities in the Five S approach.
  • Describe planned maintenance.
  • Describe quality maintenance.
  • Describe kaizen.
  • Describe the training that is most important to TPM.
  • Describe the role of safety in TPM.
  • Describe the purpose of office TPM.
Vocabulary Term

autonomous maintenance

An aspect of maintenance in which tasks, such as lubricating or cleaning, are performed by the machine operator rather than the maintenance staff. Autonomous maintenance is critical in total productive maintenance approaches.


The percentage of time a machine is actually ready for production out of the time that it should be available. Availability includes breakdowns, setups, and adjustments.

basic condition

The expected good state of repair that equipment should possess in order to produce quality parts in a timely manner. Under TPM, operators are expected to maintain their machine's basic condition.


An unproductive period when machine productions cease. Downtime is often due to mechanical failure or maintenance needs.

Five S

5S. A targeted list of activities that promote organization and efficiency within a workspace. The Five S steps are: sort, set in order, sweep, standardize, and sustain.


A Japanese word that means "change for the better." Kaizen is a method of continuous improvement that requires everyone in the company to seek and eliminate waste and errors.

kaizen event

An improvement tool that brings together employees from various departments to examine a problem, propose solutions, and implement changes. Kaizen events usually take place over one or two days.


An approach to manufacturing that seeks to reduce the cycle time of processes, increase flexibility, and improve quality. Lean approaches help to eliminate waste in all its forms.

office TPM

Application of TPM principles to the administrative areas of the company. Office TPM can involve maintaining computer equipment and eliminating sources of waste in the office area.

overall equipment effectiveness

OEE. A measure of how effectively equipment is being used. OEE percentage is determined by multiplying the equipment's availability, quality, and performance percentages together.

performance rate

The rate at which parts are produced divided by the machine capacity. Performance rate includes parts produced in a given time, reduced speeds, idling, and short-term stoppages.

planned maintenance

Maintenance that is performed purposely and regularly in order to prevent machine deterioration or breakdown. Planned maintenance is a part of TPM that keeps machines running efficiently.


An approach to manufacturing that focuses on customer satisfaction. Quality products conform to specifications, are free of defects, and meet the requirements of their anticipated use.

quality maintenance

Maintenance focusing on tasks that keeps machines producing quality, error-free parts. Quality maintenance is one aspect of total productive maintenance.

quality rate

The percentage of good parts out of the total produced parts. Quality rate includes both time lost to defects and the time from startup to normal production.

Setting In Order

The second step in 5S which requires reorganizing workplace materials to ensure easy access and to optimize efficiency. Setting In Order is sometimes known as "straightening."

six big losses

Areas in manufacturing where the greatest amounts of materials and time are wasted. The six big losses include breakdowns, setup and adjustment time, idling and minor stoppages, speed reduction, quality defects, and startup losses.


The first step in 5S that requires separating unnecessary material from necessary materials in the workplace. Sorting eliminates clutter and creates additional space.


The fourth step of 5S which requires establishing company-wide practices. Standardizing practices helps to maintain a clean, orderly, and efficient workplace.


The fifth step in 5S which requires long-term maintenance of the 5S program. Sustaining requires an on-going commitment to 5S improvements.


The third step of 5S which requires that all areas of the work environment are cleaned and inspected. Sweeping is sometimes known as "shine."

total productive maintenance

TPM. A comprehensive maintenance approach that focuses on continuous attention to the condition of production machinery and facilities. TPM's main goal is to maximize equipment usefulness in order to increase production and reduce waste.


Any thing or process that does not add value to a product. Scrap is the most common form of waste.