Training Snapshot: Achieving Total Process Reliability through TPM

If you have ever you wanted to peak under the hood of Marshall Institute training content now’s your chance. I will be revealing content from our industrial maintenance and reliability public seminars in this Training Snapshot series.  This is my third post in the series. In addition to this post I suggest you take a look at the two posts I have shared on:

In this post we are looking into our Achieving Total Process Reliability through TPM seminar.  Marshall Institute was forged in the crucible of Preventive Maintenance and TPM theory and practice. This subject is core to our company and culture and the seminar is our flagship course. The content below is taken from the first of eight sections.  In section 1 we introduce the basics of Total Productive Maintenance (aka TPM). From this section I will share what TPM is, and just as important, what it’s not, followed by the key 5 TPM activities and goals.  I wrap up the snapshot with the 5 philosophies and the 3 principles. Enjoy.


The Road to Reliability

The Road To Reliability



A partnership between maintenance, operations, and engineering (and others) for…

  • Better equipment care
  • Selecting new equipment
  • Spare parts cost reduction
  • Training cost reduction
  • Equipment changeover reduction
  • Maintainability improvement
  • Life Cycle Cost reduction
  • Eliminating recurring equipment issues
  • Transferring skills and knowledge
  • Focused on improving the reliability, efficiency, and effectiveness of the process
  • A structured approach for managing the change in culture from reactive to proactive
  • A means to develop standards and visual controls for improving the care of the equipment


TPM/TPR is a methodology to improve process reliability by involving all affected employees

TPM/TPR Philosophy

What TPM/TPR Is Not!

  • It is not just a maintenance program…
  • it is an operations improvement process!
  • It is not just Autonomous Maintenance (Basic Equipment Care)…
  • operator involvement is just a piece of the process!
  • It is not a program or an event…
  • it is a process!
  • It is not a quick fix…
  • it takes 5 plus years to achieve World Class TPM/TPR! But the results begin immediately! 


Activities and Goals of TPM/TPR

TPM/TPR Activities and Goals


Principles of TPM/TPR

Philosophy of TPM/TPR—Reflected in 5 Major Focuses

TPM/TPR is the reliability, effectiveness, and efficiency of equipment through:

  1. Natural work groups focused on improving equipment effectiveness and reliability
  2. Improving maintenance effectiveness and performance
  3. Sharing equipment care responsibilities
  4. Improving knowledge and skills
  5. Improving how equipment is designed, manufactured, and installed


The 3 Principles of TPM/TPR

  1. Find it: Inspect, detect, and then correct small defects using preventive, predictive, and operator care techniques
  2. Fix it: Return equipment to optimal conditions
  3. Keep it fixed:  Sustain and improve inspection and repair, and eliminate chronic problems

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