--- title: "TPM pillars and OEE calculation" subject: "Industrial Engineering and Management" chapter: 7 key: "semester_6/industrial_engineering_and_management:tpm-pillars-and-oee-calculation" source: https://www.bctengineer.com/q/semester_6/industrial_engineering_and_management/tpm-pillars-and-oee-calculation site: BCT Engineering --- # TPM pillars and OEE calculation Industrial Engineering and Management · Chapter 7: Plant Maintenance - Asked in: year not given, 4+4 marks - Video: [What is TPM -Total Productive Maintenance ? | 8 TPM pillars Total Productive Maintenance](https://www.youtube.com/watch?v=rcrF7zV0qOQ) — Digital E-Learning - Answer checked by Claude Opus 5.5 (high effort) on 2026-10-14 - Page: https://www.bctengineer.com/q/semester_6/industrial_engineering_and_management/tpm-pillars-and-oee-calculation - Whole chapter: https://www.bctengineer.com/md/semester_6/industrial_engineering_and_management/chapter-7 ## Question (a) Explain Total Productive Maintenance (TPM) and its main pillars. (b) A machine runs 480 minutes in a shift with 30 minutes planned break. There is 45 minutes of breakdown downtime. The ideal cycle time is 1 minute per unit; the machine produced 340 units, of which 12 were defective. Calculate availability, performance, quality rate and OEE. ## Short answer TPM involves all employees in equipment care to achieve zero breakdowns, defects, and accidents. Pillars: autonomous and planned maintenance, focused improvement, quality maintenance, early equipment management, training, safety, office TPM. OEE: availability = 405/450 = 90.0%, performance = (1×340)/405 = 84.0%, quality = 328/340 = 96.5%, OEE = 0.900×0.8395×0.9647 = 72.9%. ## Answer #### (a) TPM **Total Productive Maintenance** (developed in Japan by Nippondenso and promoted by Seiichi Nakajima) is a company-wide approach in which all employees, from top management to operators, take part in keeping equipment in the best condition. Its aim is zero breakdowns, zero defects and zero accidents. The operator performs routine cleaning, lubricating and inspection (autonomous maintenance), while the maintenance staff do specialised work. #### Main pillars (8 pillars) 1. **Autonomous maintenance (Jishu Hozen):** operator cleans, inspects, lubricates. 2. **Planned maintenance:** scheduled and predictive maintenance. 3. **Focused improvement (Kobetsu Kaizen):** remove losses by small team projects. 4. **Quality maintenance:** keep equipment conditions that give defect-free product. 5. **Early equipment management:** new equipment designed for easy maintenance. 6. **Training and education.** 7. **Safety, health and environment.** 8. **Office TPM:** remove waste in administration. The base is 5S. The six big losses are breakdown, set-up and adjustment, idling and minor stops, reduced speed, process defects and start-up losses. #### (b) Overall equipment effectiveness Planned production time $= 480 - 30 = 450$ min. Operating time $= 450 - 45 = 405$ min. $$ \text{Availability} = \frac{405}{450} = 0.900 $$ $$ \text{Performance} = \frac{\text{ideal cycle time} \times \text{total units}}{\text{operating time}} = \frac{1 \times 340}{405} = 0.8395 $$ $$ \text{Quality} = \frac{340 - 12}{340} = 0.9647 $$ $$ OEE = 0.900 \times 0.8395 \times 0.9647 = 0.7289 $$ **Answer: Availability 90.0%, performance 84.0%, quality 96.5%, OEE = 72.9%.** ## Check yourself The answer's key points as multiple-choice questions, with the correct option and why. 1. What is the central idea of TPM? A. Only the maintenance department keeps equipment in order B. Maintenance is outsourced entirely C. Repairs are done only after failure D. All employees, including operators, take part in keeping equipment in best condition, aiming at zero breakdowns, defects and accidents Answer: D. TPM is company-wide; operators do routine cleaning, lubrication and inspection (autonomous maintenance). (Key point: TPM idea) 2. Shift 480 min, 30 min planned break, 45 min breakdown. What is availability? A. 405/450 = 90.0% B. 405/480 = 84.4% C. 450/480 = 93.8% D. 435/480 = 90.6% Answer: A. Planned time = 450, operating time = 450 - 45 = 405, availability = 0.900. (Key point: Availability) 3. Ideal cycle time 1 min, 340 units produced, operating time 405 min. What is performance? A. 340/450 = 75.6% B. 340/405 = 84.0% C. 328/405 = 81.0% D. 405/340 = 119% Answer: B. Performance = ideal cycle time x total units / operating time = 340/405 = 0.8395. (Key point: Performance) 4. With 12 defective of 340 units, what is OEE? A. 90.0% (availability alone) B. 84.0% C. 72.9% D. 96.5% Answer: C. Quality = 328/340 = 0.9647; OEE = 0.900 x 0.8395 x 0.9647 = 0.729. 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