TPM-4

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TPM 4 (Totally Productive Maintenance) created by Seiichi Nakajima in the 1970s is a production maintenance system aiming at eliminating the three wastes (Muda – defects, over-production, and unnecessary motion; Muri – strain on people and machines and Mura – unevenness in production).

TPM 4 has been widely utilized in industrial production and it is a proven effective method since the 30+ years it has been applied in many companies and organizations. It is a 4 step process that strives to optimize reliability, maintainability, and operability of production systems and equipment. The steps are Autonomous Maintenance, Planned Maintenance, Early Equipment Management, and Quality Maintenance.

Autonomous Maintenance is the first step of TPM 4 and basically means allowing the operator themselves to take on the responsibility of maintaining the machine and equipment used in the production process. This step involves infrastructure reliability and preventive maintenance, supporting the operators to maintain the installation, diagnosing faults, and troubleshooting the system. All of this helps to improve the framework for optimizing reliability.

The second step in TPM 4 is called Planned Maintenance and involves using maintenance plans for preventive maintenance programs. Here, maintenance plans consist of generated procedures as well as feedback on machines and systems about their maintenance tracking. At this stage, any maintenance tools needed are provided and managed on a planned basis, such as fixing of manufactured parts. This step allows for monitoring of maintenance done regularly with the aim of maximizing the life of equipment.

The third step is Early Equipment Management, which focuses on checking a system before and after production. This step can be further divided into two parts - the pre-production part and the post-production part. The pre-production part checks for anything that may cause abnormal machinery performance or maintenance during production, such as lubricant, temperature, vibration, etc. The post-production part, on the other hand, consists of measures which salvage and reuse parts of a machine which have become unusable during production. Reusing these parts as spare parts aids in reducing machine costs and time.

The fourth and last step of TPM 4 is called Quality Maintenance and it deals with quality improvement of the production system. This step checks for any parts which contribute to defective products and takes measures to improve it. Quality maintenance basically involves understanding the production process and the quality management of the system. This includes analysing areas which negatively affect the production of quality products and finding ways to make it better.

All the four steps of TPM 4 work together and are aimed at optimizing production reliability, maintainability, and operability cost-effectively. It can also be customized to a company’s or organization’s needs and requirements. In the long run, TPM 4 is an effective system for reducing defects and maximizing production for any production system.

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