TPM: Method and approach for increased productivity

Discover the TPM method, which will improve the production time of your devices by reducing downtime and breakdowns.


Objective zero failure with the TPM method, Total Productive Maintenance

Do you want to reduce time and wasted resources ? Produce more efficiently and reduce waste at a lower cost.

Choose the TPM method Total Productive Maintenance, which improves the productivity of your equipment by reducing downtime and breakdowns. While optimising productivity, quality and other performance indicators.


Definition of the maintenance's technique : the TPM


The TPM method, Total Productive Maintenance, is a practice aimed at building a corporate culture that improves the efficiency of the production system. It allows the gradual transition from a curative maintenance system to preventive maintenance, or even predictive maintenance in some cases.

This is the result of a managerial focus on:
  Establishing a Continuous Improvement Policy
  Involving all staff by empowering them
  Improving performance QUALITY / COSTS / DEADLINES
  Improving equipment (productivity, efficiencies, etc.)..

The signification of the TPM, Total Productive Maintenance


Considering all aspects of maintenance, involve everyone in it


Ensuring maintenance by producing and penalising production as little as possible


Maintainenance: repair, clean and grease. Spending time on this

History of TPM, Total Productive Maintenance

SESA SYSTEMS cleaning station for example of the TPM method

TPM succeeded the American Preventive Maintenance (PM) and was developed in Japan after the Second World War.
TPM was introduced in the factories of the Nippondenso group before being formalised by the JIPM, Japan Institute of Plant Management.
In 1989, the JIPM defined 8 pillars on which a TPM approach is based to achieve a high level of industrial performance.
TPM is a registered trademark of JIPM.

What has changed in relation to PM is the participatory approach, the active participation of operators who know their machine(s) and therefore contribute effectively to its maintenance.

Character SESA SYSTEMS for example of the TPM method


Purpose of the TPM approach, Total Productive Maintenance


The TPM approach, Total Productive Maintenance, focuses on the machine. It is increasingly becoming the first step in launching performance improvement initiatives.

To do this, the company must have eliminated the unexpected and chance in its production activities.

To be efficient, a site needs a reliable and available production tool.

Character SESA SYSTEMS maintenance application maintenance TPM method
Character SESA SYSTEMS tool application tool TPM method

The TPM, Total Productive Maintenance allows you to visualise easily and graphically the main indicators and the factors that influence their results. These graphs provide reports, based on TPM criteria, delivering customised analysis for projections of specific time or resources.

The purpose of data analysis is to determine the main causes of underperformance and to focus on progress actions on the causes that generate the largest gains in OEE, Overall Equipment Effectiveness.

TPM systems have three main objectives:
- Minimise under-utilisation of equipment that causes large losses, including financial losses
- Participate in the conservation of equipment through a real follow-up of maintenance
- Improve the organisation and act on the factors that enable the best returns.

Advantages of the method TPM, in terms of direct results

Establishment of maintenance and cleanliness on workstations and their environment

Setting up a visual organisation

Eliminating waste of time and material

Improvement of equipment monitoring

General improvement of the environment

Behaviour benefits of the method TPM

Communicate and involve everyone

Reconsider your habits


Making sustainable the results achieved and progressing continuously

Respecting commitments and collective rules

Examples of the TPM ussefulness

SESA SYSTEMS application maintenance station to successfully implement the TPM method
SESA SYSTEMS application maintenance station to successfully implement the TPM method

Maintenance station with TPM

The maintenance station is associated with each machine or manufacturing cell requiring immediate availability of tools for:

  Meet preventive maintenance requirements

  Reduction of space requirements

  Optimisation of the working space and creation of a clean, tidy and rational space

TPM cleaning station

This management technique offers a complete solution within the company, services and offices such as:

  An increase in organisation and quality of work

  An increase in productivity and efficiency

  Accidents and technical breakdowns or malfunctions reduction

SESA SYSTEMS Cleaning Station application to successfully implement the TPM method
SESA SYSTEMS Cleaning Station application to successfully implement the TPM method

Visual and communication support SESA SYSTEMS application to successfully implement the TPM method
Visual and communication support SESA SYSTEMS application to successfully implement the TPM method

TPM visual communication support

The management of anomalies is approved with the largest industrial groups which allow operators to:

  Express yourself in real time and without constraint

  Implementation is fast, efficient, simple and economical

  To encourage better overall performance



The TPM, Total Productive Maintenance approach improves the production capacity of technical resources by building a system that avoids losses and waste such as "zero accidents, zero faults and zero breakdowns". This technique is based on fieldwork (Gemba) and concret (Genbutsu) throughout the life cycle of the production system.

The TPM involves the participation of all divisions, not only those related to production but also the conception of production, development, marketing and administrative services, and this, at all hierarchical levels, from managers to operators.

It enables to reach the "zero losses" by engaging in small group improvement initiatives.

Everyone must find an advantage in the TPM approach and this is not always the financial aspect even if it is put forward. This argument sometimes masks deeper needs.

One of the indeniable advantages for operators is that "it feels good to remove the thorn in your side".

This thorn can be as well the routine that one perceives, the attitude of the hierarchy, the feeling of not being heard as the difficulties that one encounters to carry out its work in normal conditions (difficulties due to the material, the raw materials, the organisation). This thorn can also be the need to feel useful, to be able to solve the problems encountered.

To go further

The TPM-PDCA-SUGGESTION Starter Kit:Simple development of a PDCA board, improvement proposals (suggestion) and TPM(Total Productive Maintenance) as part of a pilot project following the game.

Results: collective and effective success.



SESA SYSTEMS creations for the TPM method