In the context of factories increasingly moving towards smart manufacturing and performance optimization, simply repairing machinery when a malfunction occurs is no longer a suitable approach.

Instead, many businesses are adopting TPM (Total Productive Maintenance) to minimize losses, enhance equipment reliability, and improve production efficiency.

TPM is not just a maintenance method, but also a management philosophy that involves the entire enterprise in maintaining and optimizing the operational performance of machinery and production lines.

I. What is TPM (Total Productive Maintenance)?

TPM (Total Productive Maintenance) is a management method developed in Japan with the goal of:

• Maximizing equipment performance
• Reducing breakdowns and downtime
• Improving production efficiency
• Extending machine lifespan
• Building a culture of continuous improvement

The difference with TPM is that not only is the maintenance department responsible for the equipment, but all departments, from operators, engineers, production to management, participate in the process of maintaining operational efficiency.

II. Objectives of TPM

TPM aims to eliminate losses in the production process to achieve:

• Zero Breakdown (No machine failures)
• Zero Defect (No defective products)
• Zero Accident (No workplace accidents)

This also serves as a foundation for businesses to build a stable production system and enhance their competitiveness.

III. Why is TPM becoming increasingly important in manufacturing plants?

In today’s FMCG, F&B, or packaging factories, where production lines operate continuously at very high speeds, with many SKUs and frequent changeovers, even a small incident can reduce output, affect delivery schedules, and increase operating costs. TPM helps businesses shift from a “repair only when a machine breaks” model to a proactive maintenance model, helping to detect and address problems before they become major incidents.

IV. How are TPM and OEE related?

One of the most important goals of TPM is to improve the OEE (Overall Equipment Effectiveness) index. OEE is composed of three components:

1. Availability

This assesses the ratio of actual equipment operating time to planned production time. Availability decreases with unplanned machine downtime, prolonged setup, or unplanned downtime.

2. Performance

Performance is an indicator that assesses the actual operating speed compared to the design speed. Performance is affected by micro-downtime, slow production lines, or reduced line speed.

3. Quality

Quality is an indicator that assesses the percentage of products meeting standards on a production line. Quality decreases with the following errors: defective products, rework, scrap, or startup errors.

TPM is designed to improve all three of these components simultaneously to enhance overall OEE.

V. Six Big Losses: The Foundation of TPM

One of the most important concepts in TPM is the Six Big Losses. This model helps businesses categorize the main causes of reduced OEE into three groups:

1. Availability Group

• Breakdown Losses
• Setup & Adjustment Losses

2. Performance Group

• Idling & Minor Stops (Micro Downtime)
• Reduced Speed ​​Losses

3. Quality Group

• Startup Rejects
• Production Rejects

Through analyzing the Six Big Losses, businesses can accurately identify the causes of performance loss and prioritize appropriate improvement activities.

(ảnh)

► Read more: Six Big Losses Affecting OEE in Manufacturing

VI. TPM in Modern Factories

While TPM previously relied primarily on manual inspection and record-keeping, many businesses now integrate TPM with digital solutions. Data is collected directly from PLCs, sensors, production equipment, and packaging lines to monitor in real time indicators such as OEE, downtime, availability, performance, quality, and bottlenecks in the production line. Digitizing data helps businesses detect losses faster and make more accurate decisions.

VII. The Role of Automated OEE Measurement Systems in TPM

An automated OEE measurement system not only displays OEE figures but also helps businesses:

• Record downtime in real time
• Monitor micro-downtime
• Analyze the causes of machine downtime
• Measure actual operating speed
• Identify bottlenecks in the production line
• Automatically generate Six Big Losses statistics

Instead of compiling data using Excel or end-of-shift reports, managers can see the performance of the entire production line as soon as a problem arises.

VIII. Conclusion

TPM (Total Productive Maintenance) is not just a method of equipment maintenance, but also a foundation for businesses to build a stable production system, reduce losses, and improve OEE. Combining TPM with real-time data and an automated OEE measurement system will help businesses:

• Reduce downtime
• Control the Six Big Losses
• Improve line efficiency
• Improve OEE
• Optimize production efficiency

In the trend of data-driven manufacturing, TPM is becoming one of the important management methods that helps factories operate more efficiently and competitively. Learn how the i-OEE system helps monitor OEE, downtime, and the Six Big Losses in real time. Leave your information now, and we will contact you!

i-Soft Joint Stock Company – specializing in providing digital factory software solutions

► Add: No. 115 N2 Street, Long Truong Ward, Ho Chi Minh City

► Hotline: +84 98 973 94 88

► Email: info@i-soft.com.vn