Total Productive Maintenance (TPM)
We deploy the eight pillar TPM model so that autonomous maintenance, focused improvement and planned maintenance work together across your plant
Total Productive
Maintenance (TPM)
Total Productive Maintenance puts the Nakajima eight pillar framework to work across your operation. The pillars cover autonomous maintenance, planned maintenance, focused improvement, quality maintenance, early equipment management, training, safety and health and environment, and TPM in the office. Our team uses them to make every operator a maintainer and every maintainer a problem solver. We start with a single pilot cell, prove the model on the floor and then roll it out plant wide.
Our implementation model
A practical, phased delivery approach that runs from gap assessment through operational embedding and is built around your regulatory context.
Assess current TPM maturity against the 8 pillars, autonomous maintenance, planned maintenance, focused improvement, education, etc.
Select pilot equipment / cell for initial TPM deployment, develop pilot team, KPI baseline, and 1 year roadmap.
Implement Step 1 to 7 autonomous maintenance, operator cleaning, abnormality detection, lubrication, basic maintenance ownership.
Align planned maintenance with autonomous maintenance, preventive scheduling, predictive monitoring, spare parts optimisation.
Deploy focused improvement teams on chronic loss areas, OEE / MTBF / MTTR tracking, root cause elimination.
Scale validated pilot to plant wide TPM, education and training programme, TPM steering committee governance.
Total Productive in full scope
Value of Total Productive Maintenance (TPM)
- Operators learn to spot hazards as they clean and inspect
- Equipment defects surface early before they fail
- A clean workplace removes fire and slip hazards
- Standard work removes the need to improvise
- Your programme aligns with ISO 55001
- You can show customers a working TPM system on request
- Your maintenance records stand up to scrutiny with clear evidence
- Your practices meet recognised industry benchmarks
- Mean time between failures typically improves two to five times
- Breakdowns happen far less often
- Stable equipment delivers more consistent product quality
- Operators become more engaged in the equipment they run
- Maintenance cost falls by roughly twenty to forty percent
- Spares holdings are right sized to real need
- Costly emergency repairs are avoided
- Productivity rises as uptime grows
Codes & standards we work to
Triggers that signal the need
Where Total Productive Maintenance (TPM) applies
Wellheads, separators, gas compression, FPSO topsides, produced water systems.
Distillation columns, reactors, heat exchangers, storage spheres, LPG handling.
Cryogenic exchangers, liquefaction trains, BOG compressors, storage and sendout.
Reactive systems, batch reactors, solvent handling, runaway reaction scenarios.
Boilers, HRSGs, steam headers, hydrogen systems, ammonia SCR units.
Sterile vessels, CIP/SIP, pressure fermenters, solvent recovery, spray dryers.
Tangible deliverables
- A TPM maturity assessment
- A pilot cell plan with clear KPIs
- Autonomous maintenance standards
- A planned maintenance integration specification
- Charters for your focused improvement teams
- A plant wide rollout roadmap
Ready to start your project?
Speak with our team to scope an engagement tailored to your facility, regulatory context, and lifecycle stage.