TPM (Total Productive Maintenance) is a systematic approach to maintaining and improving production processes and equipment. Think of it as a way to keep machines running smoothly while reducing waste and increasing efficiency. It's like having a well-oiled machine where everyone, from operators to maintenance staff, works together to prevent problems before they happen. TPM is often confused with TPM (Technical Program Manager) in tech companies, but in manufacturing and process improvement, it focuses on equipment care and workplace organization. It's similar to other improvement methods like Lean Manufacturing or Six Sigma, but specifically focuses on equipment reliability and workplace organization.
Implemented TPM program resulting in 30% reduction in equipment downtime
Led Total Productive Maintenance initiatives across 3 manufacturing plants
Trained 50+ employees on TPM principles and standard operating procedures
Typical job title: "TPM Coordinators"
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Q: How would you implement a TPM program in a facility that has never used it before?
Expected Answer: Should discuss step-by-step approach including initial assessment, training needs, pilot programs, measuring results, and full rollout strategy. Should mention importance of getting buy-in from both management and shop floor workers.
Q: How do you measure the success of a TPM program?
Expected Answer: Should mention specific metrics like Overall Equipment Effectiveness (OEE), downtime reduction, maintenance costs, and productivity improvements. Should also discuss how to track and present these metrics to different audiences.
Q: What are the 8 pillars of TPM and why are they important?
Expected Answer: Should be able to explain the main pillars (like autonomous maintenance, planned maintenance, quality maintenance) in simple terms and give practical examples of each.
Q: How do you engage operators in the TPM process?
Expected Answer: Should discuss training methods, creating standard procedures, involving operators in daily maintenance tasks, and building a culture of ownership.
Q: What is the difference between preventive and predictive maintenance?
Expected Answer: Should explain that preventive maintenance is regular, scheduled maintenance while predictive maintenance involves monitoring equipment condition to predict when maintenance will be needed.
Q: What is 5S and how does it relate to TPM?
Expected Answer: Should explain 5S as a workplace organization method (Sort, Set in order, Shine, Standardize, Sustain) and how it creates the foundation for successful TPM implementation.