{"id":14451,"date":"2023-12-08T11:29:54","date_gmt":"2023-12-08T18:29:54","guid":{"rendered":"https:\/\/limblecmms.com\/?page_id=14451"},"modified":"2025-03-24T14:07:42","modified_gmt":"2025-03-24T20:07:42","slug":"total-productive-maintenance","status":"publish","type":"page","link":"https:\/\/limblecmms.com\/learn\/definitions\/total-productive-maintenance\/","title":{"rendered":"Total Productive Maintenance"},"content":{"rendered":"<div class=\"wpb-content-wrapper\"><p>[vc_row full_width=&#8221;stretch_row&#8221; kd_background_image_position=&#8221;vc_row-bg-position-top&#8221; css=&#8221;.vc_custom_1686168792651{background: #152232 url(https:\/\/limblecmms.com\/wp-content\/uploads\/blog-header-hex-bg4.webp?id=9266) !important;background-position: 0 0 !important;background-repeat: no-repeat !important;}&#8221;][vc_column css=&#8221;.vc_custom_1683307506642{padding-bottom: 80px !important;}&#8221;]<header class=\"kd-section-title col-lg-8 vc_col-sm-8 text-center  subtitle-below-title    vc_custom_1697195016544\" ><h1 class=\"separator_off\" style=\"color: #ffffff;font-size: 50;\">Total Productive Maintenance<\/h1><h2 class=\"subtitle\" style=\"color: #ffffff;font-size:15px;\">Everything you ever needed to know about total productive maintenance.<\/h2><\/header><a  href=\"https:\/\/limblecmms.com\/resources\/cmms-buyers-guide\/\"  target=\"_self\"  title=\"\"  class=\"tt_button tt_primary_button btn_primary_color  button-center button-action-link   vc_custom_1742846860820\" ><span class=\"prim_text\">Free CMMS Buyer's Guide<\/span><\/a>\n      <div class=\"entry-meta\">\n         <span class=\"published\">\n            <span class=\"far fa-clock\" aria-hidden=\"true\"><\/span>Last updated on March 24, 2025<\/span>\n            <span class=\"author\"><span class=\"far sway-author-meta\" aria-hidden=\"true\"><\/span>\n            <span>bBrinton<\/span>\n         <\/span>\n      <\/div>\n\n   [\/vc_column][\/vc_row][vc_row kd_background_image_position=&#8221;vc_row-bg-position-top&#8221; css=&#8221;.vc_custom_1687442797424{margin-top: 40px !important;}&#8221; el_class=&#8221;limble-page-blog-width&#8221;][vc_column][vc_column_text]<\/p>\n<h2>What is Total Productive Maintenance (TPM)?<\/h2>\n<p><span style=\"font-weight: 400;\">Total productive maintenance (TPM) is a methodology designed to improve production systems by <\/span><i><span style=\"font-weight: 400;\">preventing <\/span><\/i><span style=\"font-weight: 400;\">problems. Its goal is to improve product quality, minimize delivery time, and reduce costs by eliminating:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Equipment breakdowns<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Product defects<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Unplanned downtime<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Accidents<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Waste<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">TPM is an operating philosophy that enlists all company employees in a proactive, multilayered approach to maintenance.\u00a0<\/span>[\/vc_column_text][\/vc_column][\/vc_row][vc_row kd_background_image_position=&#8221;vc_row-bg-position-top&#8221; css=&#8221;.vc_custom_1687442797424{margin-top: 40px !important;}&#8221; el_class=&#8221;limble-page-blog-width&#8221;][vc_column][vc_column_text]<\/p>\n<h2><span style=\"font-weight: 400;\">Table of Contents<\/span><\/h2>\n<p><a href=\"#process\"><span style=\"font-weight: 400;\">The role of maintenance in a facility management<\/span><\/a><br \/>\n<a href=\"#types\">In-house vs outsourcing of facilities maintenance work<\/a><br \/>\n<a href=\"#examples\">How to automate and streamline facilities maintenance\u00a0<\/a><br \/>\n<a href=\"#last\">Implement Limble CMMS as your facilities maintenance software<\/a>[\/vc_column_text][\/vc_column][\/vc_row][vc_row kd_background_image_position=&#8221;vc_row-bg-position-top&#8221; css=&#8221;.vc_custom_1687440273251{margin-top: 40px !important;}&#8221; el_class=&#8221;limble-page-blog-width&#8221;][vc_column][vc_column_text]<\/p>\n<h2>Examples of Total Productive Maintenance<\/h2>\n<h3 id=\"process\">The TPM model<\/h3>\n<p><span style=\"font-weight: 400;\">The TPM model starts with a set of company-wide principles called the 5-S Foundation.<br \/>\nThat foundation supports the eight pillars of TPM \u2014 distinct techniques designed to assist and improve equipment reliability.<\/span><\/p>\n<h3><b>What is the 5-S methodology?<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">The 5-S methodology is an organizational technique derived from Japanese concepts of organizing space. By following the 5-S concepts, organizations can create high-quality work environments that enhance worker effectiveness, efficiency, and mental well-being. It also reduces waste and optimizes worker and equipment productivity. <\/span><\/p>\n<h4><b>Sort (Seiri)<\/b><\/h4>\n<p><span style=\"font-weight: 400;\">Seiri involves thoroughly inspecting every item in a specific area to determine whether or not it contributes value. If an item doesn&#8217;t add value, it should be promptly eliminated.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">When you can\u2019t immediately remove the item, place it in a quarantine area or attach a red tag to signify the need for its later removal. Red-tagged items should be returned to their correct location, recycled, or disposed of. The working area must be clear of all materials except those essential for production.<\/span><\/p>\n<h4><b>Set in order (Seiton)<\/b><\/h4>\n<p><span style=\"font-weight: 400;\">Seiton translates to orderliness. The aim is to make things easy to find, use, and replace by giving them a specific home. Orderliness includes placing frequently used items together in groups, close to the workforce. Items used less often are stored centrally.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Once set in order, a 5-S diagram shows the location of materials, tools, and objects. Companies use the diagram as a reference document for staff, to assist with training new hires, and as a method of tracking revisions to ensure documentation is kept up to date.<\/span><\/p>\n<h4><b>Shine (Seiso)<\/b><\/h4>\n<p><span style=\"font-weight: 400;\">Seiso involves maintaining continuous cleanliness. The expectation is that workers will clean their workspace at least once every day, and conduct a thorough cleaning weekly. Those using the area are responsible for performing Seiso.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Workers gain ownership by taking responsibility for their equipment and workspace with the added benefit of noticing any problems, hazards, or missing equipment. These issues are then fed into the maintenance system for early rectification before they impact production.<\/span><\/p>\n<h4><b>Standardize (Seiketsu)<\/b><\/h4>\n<p><span style=\"font-weight: 400;\">Seiketsu refers to standardizing the first three practices of 5-S \u2014 making sort, set in order, and shine <\/span><a href=\"https:\/\/limblecmms.com\/blog\/standard-operating-procedure-sop\/\"><span style=\"font-weight: 400;\">standard procedures<\/span><\/a><span style=\"font-weight: 400;\">, and using schedules to mandate frequency and responsibilities.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">The procedures use photos and visual management techniques to assist workers in maintaining these standards. By standardizing all five practices, they become integrated into the organization\u2019s daily routine and form part of the quality management system, subject to regular audits.<\/span><\/p>\n<h4><b>Sustain (Shitsuke)<\/b><\/h4>\n<p><span style=\"font-weight: 400;\">Shitsuke encompasses discipline and is about taking initiative, fostering a culture of continuous improvement, and committing to the preceding four concepts without the need for constant supervision.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Workers and management continue to support each other in striving for improvement through regular audits and training.<\/span><\/p>\n<h3>The 8 pillars of TPM<\/h3>\n<p>A business can begin to build the core of TPM once it has established the 5-S foundation. The eight pillars of TPM refer to tactical, targeted initiatives that eliminate waste and improve equipment reliability.<\/p>\n<h4><b>1. Autonomous maintenance<\/b><\/h4>\n<p><span style=\"font-weight: 400;\">With <\/span><a href=\"https:\/\/limblecmms.com\/maintenance-definitions\/autonomous-maintenance\/\"><span style=\"font-weight: 400;\">autonomous maintenance<\/span><\/a><span style=\"font-weight: 400;\">, machine operators take on responsibility for their equipment by doing simple tasks like cleaning, lubrication, visual inspection, and minor maintenance. Assigning these duties to the operator enhances their skills and knowledge about the equipment.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Additional downstream effects for production include:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Identifying and addressing problems early on improves production by preventing them from evolving into major maintenance issues or causing breakdowns.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Machinery operates at an optimal level due to regular cleaning and maintenance.\u00a0<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Maintenance personnel are able to focus on higher-level maintenance tasks, further improving equipment reliability and reducing downtime.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Capital investment costs decline as equipment life extends.<\/span><\/li>\n<\/ul>\n<h4><b>2. Focused improvement<\/b><\/h4>\n<p><span style=\"font-weight: 400;\">Focused improvement identifies waste or system losses and eliminates them using a cross-functional team-based approach.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">A trained team will:<\/span><\/p>\n<ol>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Select a piece of equipment or a functional problem<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Focus on benchmarking current performance<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Identify all problems and agree on improvement goals<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Brainstorm solutions and implement them using a systematic process similar to the plan-do-check-act cycle<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Compare the final performance to the initial benchmark<\/span><\/li>\n<\/ol>\n<p><span style=\"font-weight: 400;\">Benefits of focused improvement include:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Rapid production improvements from using a consistent and repeatable approach<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">A broad base of employees trained in the technique<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">More efficient processes, products, and systems<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Improved safety performance\u00a0<\/span><\/li>\n<\/ul>\n<h4><b>3. Planned maintenance<\/b><\/h4>\n<p><span style=\"font-weight: 400;\">Planned maintenance primarily involves <\/span><a href=\"https:\/\/limblecmms.com\/maintenance-definitions\/scheduled-maintenance\/\"><span style=\"font-weight: 400;\">scheduled maintenance<\/span><\/a><span style=\"font-weight: 400;\"> tasks, which are scheduled at frequencies defined by the equipment\u2019s condition, operating performance, or maintenance history. The schedule is based on actual data to ensure equipment is neither over nor under-maintained.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Planned maintenance provides many benefits:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">It reduces unplanned stoppages due to breakdowns, increasing production capacity.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Production can be planned around maintenance in order to minimize their impact on output.\u00a0<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><a href=\"https:\/\/limblecmms.com\/blog\/maintenance-cost-explained\/\"><span style=\"font-weight: 400;\">Maintenance costs<\/span><\/a><span style=\"font-weight: 400;\"> are reduced since there is no costly <\/span><a href=\"https:\/\/limblecmms.com\/maintenance-definitions\/emergency-maintenance\/\"><span style=\"font-weight: 400;\">emergency maintenance<\/span><\/a><span style=\"font-weight: 400;\">.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Machinery life is extended, reducing the need for capital investments.\u00a0<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Product quality improves and rework rates decline.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Planning for necessary maintenance improves your ability to manage inventory.<\/span><\/li>\n<\/ul>\n<h4><b>4. Early equipment maintenance<\/b><\/h4>\n<p><span style=\"font-weight: 400;\">Early equipment maintenance, or early equipment management engages suppliers or equipment designers in planning for equipment implementation before it arrives. By considering their operating requirements ahead of time, the company can modify or improve the new equipment to ensure its seamless integration into the production environment.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">This pillar stops many start-up issues that prevent new equipment from becoming productive as quickly as possible.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">These issues can include:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Component failures<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Procuring new tooling and spares<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Poor maintainability or operability<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">Benefits of early equipment maintenance include:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Optimized equipment design<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Improved or additional safety features<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Faster installation<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Efficient equipment commissioning<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Improved or modified operability\u00a0<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Improved access for ease of lubrication and maintenance<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Modifications to assist with easy cleaning and visual inspection<\/span><\/li>\n<\/ul>\n<h4><b>5. Quality maintenance<\/b><\/h4>\n<p><span style=\"font-weight: 400;\">Quality maintenance uses a scientific approach to eliminate equipment irregularities and ensure defect-free manufacturing. It also emphasizes proactive rather than reactive maintenance and focuses on finding and <\/span><a href=\"https:\/\/limblecmms.com\/blog\/root-cause-analysis-rca\/\"><span style=\"font-weight: 400;\">rectifying root causes<\/span><\/a><span style=\"font-weight: 400;\"> of an issue rather than treating its symptoms.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Maintaining equipment well prevents faults and downstream impacts that might require products to be scrapped or reworked. It minimizes quality issues, waste, and lost revenue due to production downtime.\u00a0<\/span><\/p>\n<h4><b>6. Education and training<\/b><\/h4>\n<p><span style=\"font-weight: 400;\">TPM is a people-centered approach, relying heavily on the knowledge, attitude, and engagement of all company staff. This pillar emphasizes the continual education and training of all employees to ensure their understanding and participation in TPM.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Examples of education and training include:\u00a0<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Equipment operators being trained on their autonomous maintenance roles<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Maintenance staff improving their knowledge of preventative maintenance and reliability techniques<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Managers understanding their role in quality-improvement<\/span><\/li>\n<\/ul>\n<h4><b>7. TPM in the office<\/b><\/h4>\n<p><span style=\"font-weight: 400;\">The TPM principles used on the manufacturing floor also apply to offices and boardrooms. This ensures all departments properly support the organization\u2019s use of TPM in achieving its mission.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Requiring administration and management to practice TPM principles breaks down silo mentalities and develops interdepartmental cooperation. It also ensures a larger pool of expertise for cross-functional teams needed to implement other pillars, such as focused improvement or quality maintenance.<\/span><\/p>\n<h4><b>8. Health, safety, and the environment<\/b><\/h4>\n<p><span style=\"font-weight: 400;\">While efficient and effective production is important, this must not be achieved at the expense of employee safety or environmental sustainability.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Total productive maintenance aims to eliminate all equipment breakdowns, product defects, and accidents. Health, safety, and the environment are integral to the philosophy.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Together, the eight pillars ensure the work of all employees and cross-functional teams constantly strive to create a safe working environment, while making them \u2014 and the equipment \u2014 more productive.<\/span><\/p>\n<p>[\/vc_column_text][\/vc_column][\/vc_row][vc_row kd_background_image_position=&#8221;vc_row-bg-position-top&#8221; css=&#8221;.vc_custom_1687440273251{margin-top: 40px !important;}&#8221; el_class=&#8221;limble-page-blog-width&#8221;][vc_column][vc_column_text]<\/p>\n<h2 id=\"types\">Why is Total Productive Maintenance important?<\/h2>\n<p><span style=\"font-weight: 400;\">A well-designed and implemented TPM program improves equipment effectiveness and efficiency. It also has a measurable positive impact on other areas of a manufacturing business.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Direct benefits of TPM:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Reduced manufacturing costs through the elimination of waste, rework, and rejections<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Improved equipment availability and performance<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Improved productivity through reduced <\/span><a href=\"https:\/\/limblecmms.com\/metrics\/idle-time\/\"><span style=\"font-weight: 400;\">idle time<\/span><\/a><span style=\"font-weight: 400;\"> and small stoppages<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Improved product quality<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Fewer injuries and accidents<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Greater employee engagement<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Increased customer focus and satisfaction<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">Indirect benefits of TPM:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Enhanced workplace culture<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Improved workplace conditions<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Greater teamwork<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Improved operator machine ownership<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Greater material and resource availability<\/span><\/li>\n<\/ul>\n<p>[\/vc_column_text][\/vc_column][\/vc_row][vc_row kd_background_image_position=&#8221;vc_row-bg-position-top&#8221; css=&#8221;.vc_custom_1687440273251{margin-top: 40px !important;}&#8221; el_class=&#8221;limble-page-blog-width&#8221;][vc_column][vc_column_text css=&#8221;&#8221;]<\/p>\n<h2 id=\"examples\">Examples of successful TPM implementations<\/h2>\n<p><span style=\"font-weight: 400;\">Two businesses found great success after implementing TPM in their companies. Here are the highlights and results for each.\u00a0<\/span><\/p>\n<h3><b>Tata Steel Tubes (TST)<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">TST began implementing TPM in 2001. The goal of TPM implementation was to:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Maximize <a href=\"https:\/\/limblecmms.com\/metrics\/overall-equipment-effectiveness\/\">overall equipment effectiveness<\/a><\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Achieve 100 percent delivery compliance<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Reduce cycle time in all processes<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Attain industry leadership on cost and quality<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">Within five years, <\/span><a href=\"https:\/\/www.researchgate.net\/publication\/242349558_A_case_study_of_total_productive_maintenance_implementation_at_precision_tube_mills\"><span style=\"font-weight: 400;\">the results<\/span><\/a><span style=\"font-weight: 400;\"> revealed the following improvements:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">78% improvement in productivity (tonnes\/month)<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">92% improvement in productivity (tonnes\/man\/year)<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">59% improvement in overall equipment effectiveness<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">63% reduction in equipment breakdowns and failures<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">85% reduction in customer complaints<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">22% improvement in delivery compliance<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">140% increase in operating pro\ufb01ts<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">80-90% reduction in rejections<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Zero major accidents<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">80% reduction in minor accidents<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">10% improvement in plant yield<\/span><\/li>\n<\/ul>\n<h3><b>Asella Malt<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">Asella Malt, in Ethiopia, <\/span><a href=\"https:\/\/www.academia.edu\/8882418\/Total_Productive_Maintenance_A_Case_Study_in_Manufacturing_Industry\"><span style=\"font-weight: 400;\">conducted a six-month pilot project<\/span><\/a><span style=\"font-weight: 400;\"> at the start of 2011 to assess the value of TPM. Because the boiler plant is a major bottleneck in malt manufacturing, the study focused on this equipment and benchmarked productivity and OEE at the beginning.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">By June 2011, Asella Malt\u2019s OEE had improved from 70.35% to 80.23%, with a reduction in total losses from 64.48 hours in January to 23.55 hours in June \u2014 a 63.5% reduction.<\/span>[\/vc_column_text][\/vc_column][\/vc_row][vc_row full_width=&#8221;stretch_row_content&#8221; content_placement=&#8221;top&#8221; css_animation=&#8221;fadeInDown&#8221; kd_background_image_position=&#8221;vc_row-bg-position-bottom&#8221; css=&#8221;.vc_custom_1691073586371{margin-top: 50px !important;margin-bottom: 20px !important;padding-top: 50px !important;padding-bottom: 50px !important;background-color: #f1f6f8 !important;background-position: 0 0 !important;background-repeat: no-repeat !important;}&#8221;][vc_column css=&#8221;.vc_custom_1691073594574{padding-right: 70px !important;padding-left: 70px !important;}&#8221;]<div class=\"kd-calltoaction\" >\n                <div class=\"container\">\n                  <div class=\"cta-text-container kd-animated fadeIn\" data-animation-delay=\"200\"><div class=\"cta-text\"><h3 >Want to see Limble in action? Get started for free today!<\/h3><\/div>\n                    <\/div>\n                    <div class=\"cta-btncontainer\"><a href=\"\/get-started\/\"  title=\"\" class=\"tt_button tt_primary_button btn_primary_color  button-action-link icon_right kd-animated zoomIn\" data-animation-delay=\"200\">Start Free Trial<span class=\"fas fa-chevron-right iconita\" ><\/span><\/a><\/div>\n                <\/div>\n            <\/div>[\/vc_column][\/vc_row][vc_row kd_background_image_position=&#8221;vc_row-bg-position-top&#8221; el_class=&#8221;limble-page-blog-width&#8221;][vc_column][vc_column_text]<\/p>\n<h2 id=\"last\">Managing TPM with a CMMS<\/h2>\n<p><span style=\"font-weight: 400;\">A <\/span><a href=\"https:\/\/limblecmms.com\/cmms\/\"><span style=\"font-weight: 400;\">Computerized Maintenance Management System (CMMS)<\/span><\/a><span style=\"font-weight: 400;\"> is an essential tool in applying TPM to your organization, giving you reliable, clean, and real-time data to maximize the program\u2019s effectiveness.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">From benchmarking current performance to analyzing OEE and implementing a planned maintenance program, A CMMS provides access to all the equipment information and data your team needs. When used with an analytics engine, a CMMS will also alert operators when an asset reaches preset thresholds, allowing for replacement or repair before a stoppage occurs.<\/span><\/p>\n<h2><b>Is Total Productive Maintenance right for you?<\/b><\/h2>\n<p><span style=\"font-weight: 400;\">TPM is more than simply a maintenance strategy; it is a comprehensive operating strategy that demands a cultural shift to maximize production efficiency, quality, and effectiveness.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Through a team-based focus on continuous improvement, TPM maximizes equipment productivity while creating a safer and happier working environment. If you want to find out more about how to implement a TPM with the help of a CMMS, <\/span><a href=\"https:\/\/web.archive.org\/web\/20230330152414\/https:\/\/limblecmms.com\/signup\/?plan=business-yearly\"><span style=\"font-weight: 400;\">start a free trial<\/span><\/a><span style=\"font-weight: 400;\"> or <\/span><a href=\"https:\/\/web.archive.org\/web\/20230330152414\/https:\/\/limblecmms.com\/contact-us\/\"><span style=\"font-weight: 400;\">reach out to our support team<\/span><\/a><span style=\"font-weight: 400;\"> to learn more<\/span><b>.<\/b>[\/vc_column_text][\/vc_column][\/vc_row][vc_row full_width=&#8221;stretch_row&#8221; kd_background_image_position=&#8221;vc_row-bg-position-top&#8221; css=&#8221;.vc_custom_1541417547006{padding-top: 100px !important;}&#8221;][vc_column css=&#8221;.vc_custom_1515677064675{padding-right: 0px !important;padding-left: 0px !important;}&#8221;][vc_row_inner kd_background_image_position=&#8221;vc_row-bg-position-top&#8221;][vc_column_inner]<header class=\"kd-section-title vc_col-lg-6 vc_col-sm-8 text-center  subtitle-below-title kd-animated fadeIn   vc_custom_1679419307921\" data-animation-delay=200><h2 class=\"separator_off\" >Related Content<\/h2><h6 class=\"subtitle\" >Explore our blog for insightful articles, personal reflections and ideas that inspire action on the topics you care about.<\/h6><\/header>[\/vc_column_inner][\/vc_row_inner][vc_row_inner kd_background_image_position=&#8221;vc_row-bg-position-top&#8221; css=&#8221;.vc_custom_1541417551563{padding-bottom: 100px !important;}&#8221;][vc_column_inner width=&#8221;1\/3&#8243;]<div class=\"kd-photobox  \" ><a href=\"https:\/\/limblecmms.com\/maintenance-definitions\/building-maintenance\/\"  title=\"Read More\"><div class=\"photobox-img\"><img loading=\"lazy\" decoding=\"async\" width=\"700\" height=\"700\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/The-Ins-And-Outs-Of-A-Maintenance-Work-Request.jpg\" class=\"attachment-full\" alt=\"Maintenance Work Order Template\" title=\"The-Ins-And-Outs-Of-A-Maintenance-Work-Request\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/The-Ins-And-Outs-Of-A-Maintenance-Work-Request.jpg 700w, https:\/\/limblecmms.com\/wp-content\/uploads\/The-Ins-And-Outs-Of-A-Maintenance-Work-Request-300x300.jpg 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/The-Ins-And-Outs-Of-A-Maintenance-Work-Request-150x150.jpg 150w, https:\/\/limblecmms.com\/wp-content\/uploads\/The-Ins-And-Outs-Of-A-Maintenance-Work-Request-320x320.jpg 320w\" sizes=\"auto, (max-width: 700px) 100vw, 700px\" \/><\/div><div class=\"phb-content text-left \">\n                  <h5 >Building Maintenance<\/h5>\n                  <p ><\/p><\/div><\/a><\/div>[\/vc_column_inner][vc_column_inner width=&#8221;1\/3&#8243;]<div class=\"kd-photobox  \" ><a href=\"https:\/\/limblecmms.com\/industry\/facility-maintenance-software\/\"  title=\"Read More\"><div class=\"photobox-img\"><img loading=\"lazy\" decoding=\"async\" width=\"700\" height=\"700\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/Ultimate-Guide-To-Reliability-Centered-Maintenance.png\" class=\"attachment-full\" alt=\"reliability centered maintenance\" title=\"Ultimate Guide To Reliability Centered Maintenance\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/Ultimate-Guide-To-Reliability-Centered-Maintenance.png 700w, https:\/\/limblecmms.com\/wp-content\/uploads\/Ultimate-Guide-To-Reliability-Centered-Maintenance-300x300.png 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/Ultimate-Guide-To-Reliability-Centered-Maintenance-150x150.png 150w, https:\/\/limblecmms.com\/wp-content\/uploads\/Ultimate-Guide-To-Reliability-Centered-Maintenance-320x320.png 320w\" sizes=\"auto, (max-width: 700px) 100vw, 700px\" \/><\/div><div class=\"phb-content text-left \">\n                  <h5 >Facility Maintenance Software<\/h5>\n                  <p ><\/p><\/div><\/a><\/div>[\/vc_column_inner][vc_column_inner width=&#8221;1\/3&#8243;]<div class=\"kd-photobox  \" ><a href=\"https:\/\/limblecmms.com\/blog\/maintenance-strategy\/\"  title=\"Read More\"><div class=\"photobox-img\"><img loading=\"lazy\" decoding=\"async\" width=\"700\" height=\"700\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/IIoT-Technology-Applications-for-Maintenance-and-Asset-Management.jpg\" class=\"attachment-full\" alt=\"iiot maintenance\" title=\"IIoT Technology Applications for Maintenance and Asset Management\" srcset=\"https:\/\/limblecmms.com\/wp-content\/uploads\/IIoT-Technology-Applications-for-Maintenance-and-Asset-Management.jpg 700w, https:\/\/limblecmms.com\/wp-content\/uploads\/IIoT-Technology-Applications-for-Maintenance-and-Asset-Management-300x300.jpg 300w, https:\/\/limblecmms.com\/wp-content\/uploads\/IIoT-Technology-Applications-for-Maintenance-and-Asset-Management-150x150.jpg 150w, https:\/\/limblecmms.com\/wp-content\/uploads\/IIoT-Technology-Applications-for-Maintenance-and-Asset-Management-320x320.jpg 320w\" sizes=\"auto, (max-width: 700px) 100vw, 700px\" \/><\/div><div class=\"phb-content text-left \">\n                  <h5 >Choosing Maintenance Strategy<\/h5>\n                  <p ><\/p><\/div><\/a><\/div>[\/vc_column_inner][\/vc_row_inner][\/vc_column][\/vc_row][vc_row kd_background_image_position=&#8221;vc_row-bg-position-top&#8221;][vc_column][vc_raw_html]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[\/vc_raw_html][\/vc_column][\/vc_row]<\/p>\n<\/div>","protected":false},"excerpt":{"rendered":"<p>[vc_row full_width=&#8221;stretch_row&#8221; 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