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Flevy Management Insights Q&A
How does Total Productive Maintenance (TPM) complement traditional planned maintenance strategies?


This article provides a detailed response to: How does Total Productive Maintenance (TPM) complement traditional planned maintenance strategies? For a comprehensive understanding of Planned Maintenance, we also include relevant case studies for further reading and links to Planned Maintenance best practice resources.

TLDR TPM complements traditional planned maintenance by integrating proactive, preventive measures and employee involvement across all levels, leading to improved equipment reliability, reduced downtime, and enhanced production efficiency.

Reading time: 4 minutes


Total Productive Maintenance (TPM) is a holistic approach to equipment maintenance that aims to achieve perfect production. It emphasizes proactive and preventive maintenance to maximize the operational efficiency of equipment. TPM complements traditional planned maintenance strategies by integrating maintenance into the daily activities of all employees, from operators to managers, and by focusing on the entire life cycle of equipment. This integration leads to improved equipment reliability, reduced downtime, and increased production efficiency.

Integration with Traditional Planned Maintenance

Traditional planned maintenance strategies typically involve scheduled maintenance activities based on the manufacturer's recommendations or past failure data. While effective in maintaining equipment reliability to a certain extent, these strategies often overlook the potential for continuous improvement and employee involvement in maintenance activities. TPM, on the other hand, extends beyond scheduled maintenance to include activities that improve the overall effectiveness of equipment. It encourages a culture where everyone is responsible for maintenance, leading to early detection of problems and prevention of equipment failure.

One key aspect of TPM that complements traditional planned maintenance is its focus on Autonomous Maintenance. This involves training operators to perform basic maintenance tasks, such as cleaning, lubricating, and inspecting their equipment. By doing so, TPM reduces the burden on maintenance departments and allows for more detailed and strategic maintenance work to be planned and executed. This synergy between TPM and traditional maintenance strategies enhances the overall maintenance program, leading to improved equipment reliability and availability.

Furthermore, TPM introduces the concept of focused improvement teams or cross-functional teams that work together to solve complex equipment problems. These teams analyze equipment failures and develop solutions that prevent recurrence. By combining the strengths of TPM with traditional planned maintenance strategies, organizations can achieve a more dynamic and responsive maintenance program that adapts to changing operational needs.

Learn more about Continuous Improvement Autonomous Maintenance Planned Maintenance

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Enhancing Operational Efficiency and Reducing Downtime

TPM significantly contributes to enhancing operational efficiency by systematically reducing or eliminating the eight major losses in manufacturing, which include breakdowns, setup and adjustment losses, idling and minor stoppages, reduced speed, process defects, reduced yield, and energy and material losses. By focusing on preventive measures and continuous improvement, TPM minimizes unplanned downtime and ensures that equipment operates at its full capacity. This proactive approach to maintenance complements traditional planned maintenance by addressing the root causes of equipment inefficiencies before they result in downtime.

For example, a study by McKinsey & Company highlighted that organizations implementing TPM alongside traditional maintenance strategies experienced a reduction in equipment breakdowns by up to 50% and a 10-20% increase in production efficiency. These improvements are attributed to the systematic elimination of waste and the optimization of equipment performance through TPM's comprehensive maintenance practices.

Real-world examples of TPM's success include companies like Toyota, where TPM originated. Toyota's implementation of TPM, in conjunction with its Lean Manufacturing principles, has led to remarkable improvements in equipment effectiveness and production efficiency. This demonstrates the potential of TPM to complement and enhance traditional planned maintenance strategies, leading to superior operational performance.

Learn more about Lean Manufacturing

Creating a Culture of Continuous Improvement

One of the most significant ways TPM complements traditional planned maintenance strategies is by fostering a culture of continuous improvement. TPM encourages the involvement of all employees in maintenance activities, which leads to a deeper understanding of the equipment and processes. This collective knowledge base becomes a powerful resource for identifying improvement opportunities and implementing solutions that enhance equipment reliability and performance.

Additionally, TPM emphasizes the importance of education and training for all employees. By equipping employees with the skills and knowledge to perform maintenance tasks, organizations can ensure that their maintenance strategies are effectively implemented and sustained. This focus on education and empowerment complements traditional planned maintenance by creating a more resilient and adaptable maintenance workforce.

In conclusion, the integration of TPM with traditional planned maintenance strategies offers a comprehensive approach to equipment maintenance that leverages the strengths of both methodologies. By focusing on preventive measures, employee involvement, and continuous improvement, TPM enhances equipment reliability, operational efficiency, and production quality. Organizations that successfully integrate TPM with their existing maintenance strategies can achieve significant competitive advantages, including reduced downtime, lower maintenance costs, and improved overall performance.

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Best Practices in Planned Maintenance

Here are best practices relevant to Planned Maintenance from the Flevy Marketplace. View all our Planned Maintenance materials here.

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Explore all of our best practices in: Planned Maintenance

Planned Maintenance Case Studies

For a practical understanding of Planned Maintenance, take a look at these case studies.

Optimizing Planned Maintenance Strategy for a Global Manufacturing Firm

Scenario: A multinational manufacturing firm is grappling with escalating costs and operational inefficiencies due to an outdated and reactive Planned Maintenance approach.

Read Full Case Study

Planned Maintenance Enhancement for Aerospace Firm

Scenario: The organization is a leading provider of aerospace components facing significant downtime due to inefficient Planned Maintenance schedules.

Read Full Case Study

Planned Maintenance Advancement for Life Sciences Firm

Scenario: A life sciences company specializing in medical diagnostics equipment is facing challenges with its Planned Maintenance operations.

Read Full Case Study

Planned Maintenance Optimization for E-commerce in Apparel Retail

Scenario: An e-commerce platform specializing in apparel retail is facing challenges with its Planned Maintenance operations.

Read Full Case Study

Planned Maintenance Strategy for Aerospace Manufacturer in Competitive Market

Scenario: The organization is a key player in the aerospace industry, facing frequent unplanned downtime due to maintenance issues.

Read Full Case Study

Planned Maintenance Enhancement in Telecom

Scenario: The organization in question operates within the telecom industry, facing significant challenges maintaining its expansive network infrastructure.

Read Full Case Study

Explore all Flevy Management Case Studies

Related Questions

Here are our additional questions you may be interested in.

How can organizations ensure employee engagement and buy-in for planned maintenance initiatives?
Ensuring employee engagement in maintenance initiatives involves clear communication, Strategic Planning, participatory decision-making, recognition, and fostering a Culture of Continuous Improvement to enhance organizational performance. [Read full explanation]
What impact do predictive analytics have on the evolution of planned maintenance programs?
Predictive Analytics transforms Planned Maintenance from Preventive to Predictive, enhancing Operational Efficiency, reducing costs, and driving Innovation and Competitive Advantage through data-driven strategies. [Read full explanation]
How is the Internet of Things (IoT) reshaping planned maintenance strategies?
IoT is transforming maintenance strategies from Preventive to Predictive Maintenance, enhancing Operational Efficiency, reducing costs, and driving Innovation and Competitive Advantage. [Read full explanation]
What role does digital transformation play in enhancing planned maintenance strategies?
Digital Transformation revolutionizes planned maintenance by shifting from reactive to predictive strategies through IoT, AI, and big data, improving efficiency, reducing costs, and increasing asset reliability. [Read full explanation]
What metrics should executives use to measure the success of a planned maintenance program?
Executives should use a comprehensive set of KPIs including Cost Savings, Asset Uptime, Maintenance Response Time, Preventive Maintenance Compliance Rate, MTBF, Customer Satisfaction, Energy Efficiency, and ROI to measure Planned Maintenance Program success, driving improvements in financial and operational performance. [Read full explanation]
How can planned maintenance programs be adapted for service-oriented businesses as opposed to manufacturing?
Adapting planned maintenance for service-oriented businesses involves focusing on technology, predictive analytics, and customer experience to ensure continuous service delivery and operational efficiency. [Read full explanation]

Source: Executive Q&A: Planned Maintenance Questions, Flevy Management Insights, 2024


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