+91 90030 94106 / +91 94440 84652 ceo@marsconsultants.com

TPM consultancy

TPM consultancy


Total Productive Maintenance ( TPM) is a systematic approach to understanding the equipment’s function, the equipment’s relationship to product quality and the likely cause and frequency of failure of the critical equipment components. It prevents quality defects and breakdowns, eliminates the need for equipment adjustments, and makes the work easier and safer for equipment operators.

For the Organization:
  • Improvements in operational efficiency
  • Improvements in reliability
  • Improvements in quality
  • Lower operating cost
  • More emphasis on planning and preventative maintenance
  • Increased equipment life span
  • Higher morale from improved job satisfaction and job security
  • Improvements in inventory -cost reduction
  • Improvements in Health and Safety
  • Foundation for WCM, TQM, JIT, Lean Manufacturing
  • Better able to meet customer's quality and delivery needs
  • Improvements in production capacity / availability = increased productivity = increased $

For the Maintenance Function:
  • Maintenance partnership with production
  • Free up time to perform higher functions
  • Better trained mechanics and higher levels of expertise
  • Greater value to the organization

Improve maintenance role in organization-combat perception that maintenance is a burden, resulting in:

  • Improved morale
  • Lower turnover & hiring costs
  • Lower absenteeism

Benefits of Total Productive Maintenance ( TPM)

  • Productivity Improvement – Productivity is improved through fewer losses in the company
  • Quality Improvement – Quality is improved as a result , that the failures and malfunctions is reduced
  • Cost Reduction – THE cost is reduced because the losses and other not value added work is reduced
  • Employee Ownership – Ownership of equipment by operators through Autonomous Maintenance
  • Employee Confidence – “Zero failure”, “zero defect” and “zero accident” conditions builds employee self-confidence
  • Improved working environment – Clean working conditions provides a good working environment
  • Increased Plant Reliability
  • Customer Satisfaction – TPM leads to high delivery performance and customer satisfaction


The traditional approach to TPM was developed in the 1960s and consists of 5S as a foundation and eight supporting activities (sometimes referred to as pillars). :

The 5S Foundation

The goal of 5S is to create a work environment that is clean and well-organized. It consists of five elements:

  • Sort (eliminate anything that is not truly needed in the work area)
  • Set in Order (organize the remaining items)
  • Shine (clean and inspect the work area)
  • Standardize (create standards for performing the above three activities)
  • Sustain (ensure the standards are regularly applied)

Eight Pillars of Total Productive Maintenance ( TPM)

  • Autonomous Maintenance
  • Focus Improvement
  • Planned Maintenance
  • Training
  • Early Equipment Management (EEM)
  • Quality Maintenance
  • Efficient Administration
  • Safety & Environment

Eight Pillars of Total Productive Maintenance ( TPM)

  • Self maintained work place
  • Elimination of the 6 big losses
  • Zero breakdowns
  • Zero defects
  • Optimal life and availability of tools
  • Self-improvement
  • Short production-development time and low machine life cost
  • Productivity in indirect departments
  • Zero Accidents