TPM Lean Six Sigma Consulting in India


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Have you ever had a computer malfunction? What’s your first instinct? “Let me call the Support Department!”, Right?

Ideally, in organizations, there are dedicated maintenance & support departments. They are primarily responsible for making sure all equipment owned and managed by the organization are at their peak operating capacities. Well, that’s an outdated idea and TPM brings about a paradigm shift in how equipment is handled and maintained.

What is TPM Lean Six Sigma ?

Total productive maintenance (TPM) is a product maintenance strategy that advocates that everyone in an organization should participate in maintenance beyond just the maintenance department. The TPM strategy leverages the skillsets of all employees and seeks to assimilate maintenance activities into the day-to-day operations of an organization.

In other words, TPM (Total Productive Maintenance) is a holistic approach to equipment maintenance that strives to achieve perfect production with:

  • No Breakdowns
  • No Small Stops or Slow Running
  • No Defects
  • No Accidents

TPM emphasizes a proactive and preventive maintenance style to improve the efficiency of any equipment. Total Productive Maintenance blurs the distinction between the roles in an organization and sets a strong priority on empowering operators to help maintain the equipment they use.

TPM Lean Six Sigma Consulting in India

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Who Participates in TPM Lean Six Sigma ?

As evident above, in the total productive maintenance principles, everyone from top management to operators at the lower level should partake in maintenance. Now, how’s that possible? As simple as it is, everyone should contribute on their own merit.

Senior Management: Without a shred of a doubt, the senior management should promote TPM as their corporate policy. Additionally, the engineers in reliability practice and otherwise also need to get their hands dirty at some point as they can interpret the maintenance data stored in an organization’s database & ERPs to generate relevant metrics and actionable business insights.

Operators: Simply put, the operators are the owners of an organization’s assets i.e. they need to be accountable for the daily maintenance of the machines they operate. The accountability also includes regular cleaning & lubrication for consistent equipment health. Nobody knows machines better than the operators and they are also expected to spot early signs of deterioration and report them.

The Technicians: Not only are technicians expected to undertake total productive maintenance (TPM) training to meet TPM goals and perform more advanced preventive maintenance activities. In addition to regular maintenance, technicians also take responsibility for improvement activities that will impact the KPIs defined by engineers and senior leaders.

The Foundation of TPM Lean Six Sigma

At the very core of all TPM activities, lies the 5S foundation that inspires and sets the tone for the rest of the TPM implementation. The 5S foundation strives to create an environment in the workplace that is clean and well-organized. So, what is the 5S?

Sort: Eliminate anything that is not truly needed in the work area
Straighten: Organize the remaining items
Shine: Clean and inspect the work area
Standardize: Create standards for performing the above three activities
Sustain: Ensure the standards are regularly applied

When you have a look at the 5S Foundation, it is quite evident how the 5S creates a footing for equipment success and TPM in lean manufacturing. For example, undoubtedly, if you have a clean and well-organized work area, the tools and spares are easier to locate, it becomes simpler to spot emerging issues such as fluid leaks, material spills, metal shavings, hairline cracks in mechanisms, etc in your lean manufacturing setup. 5S is your first step in achieving TPM in lean six sigma.

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The 8 Pillars of TPM Lean Six Sigma

Implementing TPM needs to be structured well and this structure is provided by the eight pillars of TPM. The eight pillars are majorly focused on prescient and preventive techniques for improving equipment reliability. The 8 pillars are:

Autonomous Maintenance: Places responsibility for routine maintenance, such as cleaning, lubricating, and inspection, in the hands of operators.

Planned Maintenance: Schedules maintenance tasks based on predicted and/or measured failure rates.

Quality Maintenance: Design error detection and prevention into production processes. Apply Root Cause Analysis to eliminate recurring sources of quality defects.

Focused Improvement: Have small groups of employees work together proactively to achieve regular, incremental improvements in equipment operation.

Early Equipment Management: Directs practical knowledge and understanding of manufacturing equipment gained through TPM towards improving the design of new equipment.

Training and Education: Fill in knowledge gaps necessary to achieve TPM goals. Applies to operators, maintenance personnel, and managers.

Safety, Health, Environment: Maintain a safe and healthy working environment.

TPM in Administration: Apply TPM techniques to administrative functions.

Advantages of TPM Lean Six Sigma

When everyone in a company is actively contributing to TPM, a great variety of improvements can occur. TPM usually has the following benefits:

  • Fewer Breakdowns as a result of Operator & Technician awareness.
  • A proactive management approach & fewer breakdowns essentially mean a safer workplace.
  • As the efficiency of the lean manufacturing unit improves, so does performance.

Implementing TPM Lean Six Sigma

Total Productive Management isn’t some management style, it is a cultural reform for companies that strive for six sigma excellence. It needs to be smartly implemented in a structured fashion. For this very reason, top corporations opt for TPM consulting and TPM training for improving their outcomes. Total productive Maintenance consultants, such as Arrowhead Consulting in India, ensure that your lean six sigma goals are attained through TPM consulting in India and TPM training globally. Here’s a case study on how TPM if implemented helps in manufacturing companies, Source:



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