Improve NZ TPM Programs

TPM provides a complete framework for improving equipment capabilities, using a method known as Overall Equipment Effectiveness (OEE) to monitor equipment performance. OEE losses
fall into the following categories.

1. Availability Losses - breakdowns, changeovers

2. Performance Losses - speed loss, minor stoppages

3. Quality Losses - defects, rework and yield loss

We offer a range of TPM related programs including introductory training, an OEE improvement challenge, and maintenance excellence programs.

Many of our programs can be used to support a Lean or Competitive Manufacturing Program and may be eligible for funding.

Level 2 & 3 in Competitive Manufacturing

21504 Apply Quick Changeover Procedures

21509 Monitor process capabililty

21510 Apply quality standards

21515 Undertake root cause analysis

21516 Contribute to a proactive maintenance strategy

Level 4 in Competitive Manufacturing

21524 Undertake process capabiity improvements

21525 Mistake proof a production process

21528 Undertake proactive maintenance analysis

21529 Assist in implementing a proactive maintenance strategy

Diploma in Competitive Manufacturing

21533 Develop Quick Changeover Systems

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Total Productive Maintenance (TPM)

Often referred to as Total Productive Maintenance (TPM), a system originally developed by the Japanese Institute for Plant Maintenance (JIPM) TPM has become an internationally accepted program for improving plant capability.

Companies applying TPM programs have experienced significant
improvement in plant performance and communications between
operational and maintenance personnel.

In Australasia TPM programs are often referred to as “Equipment Care”, or "Proactive Maintenance" programs. These programs may be funded using the Competitive Manufacturing Training Program

Overall equipment effectiveness (TEE)

Overall Equipment Effectiveness is a measure of your plants performance. It combines the effects of lost time from availability losses, performance losses and quality losses.

It is an international standard for measuring plant and equipment performance and was developed by the Japanese Institute of Plant Maintenance (JIPM) in the early 1980’s. Many of our Manufacturing Excellence Coaches have been trained by the JIPM and used these principles in Australasia, US and the UK.

Availability losses

Typical availability losses include breakdowns, lack of an operator, waiting on other equipment, material or approvals, unplanned meetings and changeover times.

Changeover times are included as many companies can significantly reduce the time required to change from one product run to another.

The Improve Group provides in-house workshops for quick changeovers. These can be funded if included in a Competitive Manufacturing Program. For more information click

Performance Losses

Performance losses impact on the throughput capacity of the plant.

Key losses occur due to machines running at a slower rate than they were designed for – this often occurs when machines are poorly maintained, trainee operators are running the machine, or products have different characteristics – consistency, size, handling, temperature, viscosity, etc.

Minor stoppages often occur if equipment misaligns and
requires re-adjustment, product jams in the handling systems,
or equipment overheats and has to be reset.

Performance losses reduce the actual operating hours and the resultant is known as Net Operating Time.

Quality Losses

Operating time is reduced by quality losses – the time lost when producing defective product, start up losses and any reworked product.

Reworked product has a double effect as it uses time that could be used to make good product – once when it is first manufactured, and again when it is reworked. Often the rework time is longer than the original time taken to produce the product as the product needs to be reloaded and unloaded.

Quality Improvement and Six Sigma programs can make a significant difference to these losses.

Click here to contact Improve Group