Topic guide · 24 articles
TPM and maintenance
Total productive maintenance (TPM) makes equipment reliability a shared job between operators and maintenance staff, instead of leaving it to the maintenance department alone. It is built on eight pillars that rest on a 5S foundation, with autonomous maintenance at its core: operators clean, inspect, lubricate and tighten their own machines and catch small problems before they become breakdowns. These guides cover TPM and its pillars, the maintenance strategies it works alongside, and how to measure and reduce downtime with OEE and the six big losses.
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- 1
Autonomous Maintenance: The Seven-Step Process
The 7 steps of autonomous maintenance, from initial cleaning to full operator self-management. What each step produces and where AM programs usually stall.
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What are the Different Types of Maintenance Workers?
Most maintenance teams have 3 types of maintenance workers: technicians, engineers and planners. What each role does day to day and how their work differs.
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Understanding Equipment Failure: Causes and Prevention
Dive into the frequent culprits behind equipment failure and explore effective strategies to prevent these issues.
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All 24 articles on tpm and maintenance
Total productive maintenance (3)
Autonomous maintenance and CILR (4)
Maintenance strategies and teams (10)
- What are Five Types of Maintenance Strategies?
- Proactive vs Reactive Maintenance: The Difference
- Preventive vs Predictive Maintenance: Key Differences
- What are the Benefits of Preventive Maintenance?
- Planned Maintenance: Optimization Strategies for Reliability
- The Difference Between Planned and Scheduled Maintenance
- Reliability-Centered Maintenance: A Practical Guide
- What are the Different Types of Maintenance Workers?
- Maintenance KPIs: What to Measure and Why
- Why You Should Digitize Equipment Maintenance
Downtime, OEE and equipment failure (7)
- Overall Equipment Effectiveness (OEE): What is it?
- The Six Big Losses in Lean Manufacturing
- How to Reduce Manufacturing Downtime?
- Planned Downtime: What it is, the Benefits
- Understanding Equipment Failure: Causes and Prevention
- Four Most Common Causes of Equipment Failure
- Root Cause Analysis for Equipment Failures: Methods and Framework
Key terms
- Total productive maintenance (TPM)
- Eight pillars of TPM
- Autonomous maintenance
- CILR (clean, inspect, lubricate, retighten)
- Preventive maintenance (PM)
- Predictive maintenance (PdM)
- Reliability-centered maintenance (RCM)
- Planned maintenance
- Overall equipment effectiveness (OEE)
- Six big losses
- Mean time between failures (MTBF)
- Micro-stops
Where LeanSuite helps
Autonomous Maintenance
Rolls out visual CILR (clean, inspect, lube, retighten) checklists so operators catch small abnormalities before they cause downtime.
See Autonomous MaintenanceCILR Checklists
Build visual CILR checklists so operators clean, inspect, lubricate and re-tighten on schedule and catch problems before they become breakdowns.
See CILR ChecklistsMicro-stops
Log the brief jams your ERP and MES never report, and see which micro-stops cost the most so you can win back OEE.
See Micro-stopsAI SMP
Film a senior technician once and get a standard maintenance procedure with torque values, lockout steps, tools and parts.
See AI SMP
Free calculators
- OEE calculatorOverall equipment effectiveness from shift time, downtime, ideal cycle time and part counts.
- Downtime cost calculatorWhat an hour, an event and a year of unplanned downtime cost, from lost output, idle labour, scrap and overtime.
- MTBF and MTTR calculatorMean time between failures, mean time to repair and availability from operating time, failures and repair time.
FAQ
Questions about tpm and maintenance
More topics
- Lean manufacturing fundamentals
- Kaizen and continuous improvement
- Root cause analysis and problem solving
- Quality management
- 5S and visual management
- Value stream mapping and flow
- Standard work, SOPs and training
- Safety management
- Lean leadership and employee engagement
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