Double-digit productivity improvements resulting from workflow redesigns and new-capital equipment investments always get a lot of attention. But over time the returns from many smaller, more methodical changes and investments can rival more highly visible projects. Total productivity maintenance (TPM), for both existing and new equipment, offers just such an opportunity.

At the heart of an effective TPM program is the core understanding that equipment can be maintained to perform reliably with high levels of quality for many years. The five pillars of TPM are autonomous care, planned maintenance, preventive maintenance, education, and quality.

For preventive maintenance and other purposes, one of the key elements of TPM is tracking overall equipment effectiveness (OEE), which combines machine availability, performance and quality metrics. Machine availability reports time lost due to planned and unplanned downtime, including setup time, in a given period. Machine performance helps identify losses due to jams and minor stoppages that result in slower speeds than what’s standard. And the quality component of OEE exposes losses due to defects or material loss.

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