TPM Consulting
Practical articles written by consultants who work on the floor, published continuously.
The planned maintenance pillar does not start with writing a PM schedule; it starts with a failure database you can trust. Steps 0 to 7, and why the first three must target MTTR.
Predictive maintenance does not by itself make machines fail less. It buys time to plan. If the time it buys is shorter than your planning cycle, the data is worthless.
FMEA is a preventive tool: valuable before the event, merely a report after it. The ten steps, and how to make the output turn into action.
The core idea of the QM pillar: defects come from incorrect equipment conditions, not from careless people. Set the conditions correctly and hold them, and the defect cannot occur.
Most teams stop at the first plausible cause, which is usually only the mechanical one. The three lenses they never applied are why the problem returns.
Production TPM runs on five pillars; company-wide TPM adds three more. What each delivers, in what order, and the floor-level test for each.
How OEE is built, the maintenance KPIs that belong beside it, and the six recurring reasons improvement programmes stall.
How operators come to genuinely own their equipment: ownership, CLAIR, abnormality tags, and the seven steps with a pass criterion for each.
The path from reactive work to planned, condition-based and predictive maintenance — and the points where most plants stall.
When breakdown repair is only a stop-gap, P-M Analysis is the advanced tool that reaches the physical root cause of chronic loss.
Good maintenance cannot happen if things went wrong at the design stage. MP Design and LCC analysis are the tools for the decisions made before purchase.
Lean and TPM are not competing programmes. Lean removes waste from the flow; TPM makes the equipment reliable enough for that flow to hold.
Why kaizen results fade within a quarter, and the accountability structure that keeps improvement running without consultants.
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Free book · 384 pages
The complete book, by Thanee Aumor
The complete book on running TPM inside a lean factory: how equipment drives company performance, the losses, OEE measurement, all eight pillars, and how to plan the deployment in a real plant.
A three man-day assessment ends with a readiness report, the weaknesses needing urgent attention, and a TPM plan.
