The 8 pillars of TPM represent a collection of practical principles that serve as the foundation of total productive maintenance (TPM). The primary goal of the TPM pillars is to take proactive measures in the maintenance of equipment and machinery, ultimately enhancing their performance, reliability, and lifespan.

Similar to how a physical structure begins with a sturdy framework, establishing a solid TPM process relies on a firm foundation based on the principles of 5S.

1.)  5S Principles

The 5S principles encompass a series of workplace organization techniques condensed into five fundamental steps,

Sort: Sort tools, equipment, and materials to identify which items can be discarded.

Straighten: Straighten and set things in the proper order to reduce unnecessary motion and efficiently travel between working groups and locations.

Shine: Shine refers to performing necessary housekeeping to clean up the work area.

Standardize: Standardize and schedule activities to systematically form the habits to keep the workplace organized.

Sustain: Sustain the process and principles for long-term applications.

The 5S approach offers a structured method for tidying up the workplace while identifying any hidden issues or obstacles. It serves as a crucial foundation for the subsequent seven pillars of TPM, as the absence of which could lead to disorganization, lack of discipline, and inefficiency within the initiative.

2.) Autonomous Maintenance

TPM promotes the concept that those who operate the equipment may be the most suitable individuals to manage maintenance duties and equipment upkeep.
Enabling operators to handle minor maintenance tasks allows maintenance teams to concentrate on more specialized assignments. Operators have the ability to efficiently minimize downtime by promptly addressing breakdown issues and coordinating scheduled maintenance with planned downtimes.

3.) Continuous Improvement

Continuous improvement, also referred to as the Japanese concept of Kaizen, encourages the mindset of constantly striving towards minimizing losses and defects. By making small adjustments to procedures on a regular basis, the organization's overall effectiveness and efficiency improve over time.

Read Also: What Is Total Productive Maintenance?

4.) Planned Maintenance

Scheduled maintenance tasks are crucial for avoiding equipment failures. Periodically assessing the equipment's condition is key in preventing deterioration and mechanical failures before they occur.

5.) Quality Maintenance

Manufacturing processes strive for flawless production in order to guarantee customer contentment.There should be established standards to ensure exceptional quality, along with regular checks to confirm compliance with these standards. The purpose of quality maintenance is to detect any potential reasons for deviations from flawless production.Root cause analysis is a key element under the quality maintenance pillar of TPM. It is crucial to swiftly pinpoint and address any problems that arise when equipment malfunctions. Root cause analysis goes beyond by identifying and documenting the underlying problems in order to avoid future issues.

6.) Training

The concept behind TPM revolves around each individual actively contributing their part to enhance the overall productivity of the production process. Each member needs to undergo thorough training to gain both theoretical knowledge and practical skills in operating machines and equipment effectively, aiming to enhance performance and develop individual competence.

Read Also: The Role of Maintenance in Food Manufacturing

7.) Office TPM

The administrative department, operating discreetly, performs a crucial function that is frequently underappreciated. Similar to the other production teams and processes, the management and administrative functions can also benefit from enhancements in productivity. This involves the identification and removal of inefficiencies to enhance the overall operational efficiency of the plant.

8.) Health, Safety, and Environment

The final aspect of TPM is centered on establishing a secure working environment. The true essence of this pillar shines through when it is actively put into practice alongside each of the other components. Efficient execution of this principle could enhance workplace safety and minimize risks.