TPQM and quality-related maintenance

Total Planned Quality Maintenance (TPQM) is an approach that joins planned maintenance with quality management. It is based on the idea that product quality depends on equipment condition, so the machine conditions that produce good quality are identified, measured and kept under control through planned maintenance. The aim is to prevent defects at the source instead of detecting them by inspection after production.

Basic idea

Defects are caused by the "4Ms" - machine, method, material and man. TPQM controls the machine factor by:

1. Finding the relation between machine conditions (wear, vibration, temperature, alignment, tool condition) and each quality characteristic.
2. Setting standards for these conditions.
3. Checking them regularly and correcting them before they drift out of limits.
4. Recording the results and improving the standards.

 TPM (equipment effectiveness)  +  TQM (quality of product)
              \                      /
               +---- TPQM ----------+
   planned maintenance aimed at zero defects

Steps

• Make a quality-defect analysis and link each defect to a machine condition.
• Set quality-related check points in the maintenance schedule.
• Train operators to monitor and adjust them (autonomous maintenance).
• Use control charts and Pareto analysis to review the results.

Relation to TPM and TQM

TPM works for zero breakdowns, and TQM for customer satisfaction through quality. TPQM is the meeting point: it applies TPM's planned maintenance and quality maintenance pillars so that maintenance contributes directly to product quality.

Benefits

Fewer defects and less rework, lower scrap and inspection cost, longer equipment life, better delivery.