TPM Tools: Proven Techniques and Software for Successful Implementation

As highlighted on the Fiix blog, a successful TPM program follows the 5S foundation and the eight pillars. But which tools, techniques, and software will help you execute the plan you’ve drafted? LeanProduction.com lists several proven methods and solutions that can accelerate your TPM journey.

Industry Techniques

Setting Your Ideal OEE Goal

Measuring Overall Equipment Effectiveness (OEE) is critical for operationalizing your TPM strategy. One effective approach is to set a “personal best” OEE target that the entire team can pursue. Follow these steps:

• Track OEE for your TPM‑related equipment over a month, breaking the results down by shift.
• Record the best individual results for availability, performance, and quality across all shifts.
• Multiply the top value from each OEE component to calculate the “very best” OEE score. This becomes your collective benchmark.

Introducing Proactive Maintenance with a CMMS

The final step in our “putting your TPM plan into action” series was planning and scheduling maintenance activities. A CMMS can streamline this process, but you must apply specific techniques to align preventive maintenance with your TPM objectives.

1. Identify all equipment components that warrant proactive maintenance—wear points, failure hotspots, and stress points identified by thermography or vibration analysis.
2. For each component, establish maintenance intervals: wear‑based, failure‑based, time‑based, or work‑order‑based, as appropriate.
3. Create a feedback loop that includes:
   • Document every replacement in the CMMS, noting the reason for the change.
   • Conduct a monthly audit to confirm adherence to schedules, verify work‑order tracking, and validate interval relevance.
   • Adjust intervals if unscheduled maintenance or replacements occur.
   • Generate CMMS reports over time to highlight preventable issues and trends.

Sustaining TPM Over Time

Continuous improvement is the heart of any TPM program. LeanProduction recommends several strategies to keep the momentum alive and the culture vibrant.

Engage Employees

Paint a compelling future vision for the organization and show each employee how they benefit. This tackles the “what’s in it for me?” mindset and fuels motivation. Recognizing and rewarding TPM‑aligned behavior further incentivizes participation.

Succeed Early

Early wins build confidence and counter the perception that TPM is a bureaucratic burden. Allocate sufficient resources in the initial phase to achieve tangible results.

Provide Active Leadership

Without upper‑management endorsement, technicians will struggle to embrace TPM. Leaders must consistently emphasize TPM’s value and celebrate milestones to prevent regression to old habits.

Evolve Your TPM Program

The “continuous” in continuous improvement demands that the TPM framework evolves with new data and changing conditions, preventing stagnation.

Finding the Right Software

As previously noted, a CMMS supports each of the techniques mentioned above. When selecting a system, compile a requirements list, then compare and rank options. Read our latest case studies to see how industry leaders use Fiix’s CMMS software to transform their TPM programs and operations.