Introdução à manutenção produtiva total (TPM)
Total productive maintenance (TPM) is a maintenance strategy for achieving near-perfect production with no breakdowns, item defects, unplanned stops, slowdowns, or safety incidents.
A total productive maintenance program improves productivity by focusing on both equipment and the people who use it. Rather than leaving maintenance to a specialized team, TPM distributes the responsibility of routine tasks like inspections, cleaning, and basic upkeep to plant workers and machine operators., This shared responsibility helps minimize defects, boosts uptime, and extends asset life cycles.
O que é a Manutenção Produtiva Total (TPM)?
Total Productive Maintenance (TPM) is a proactive management philosophy that involves all employees in maintaining and improving equipment performance. Its goal is to eliminate defects, breakdowns, and accidents by focusing on preventive maintenance and continuous improvement.
TPM, which means total productive maintenance, is a comprehensive approach to maintenance that aims to maximize the effectiveness of production equipment. Instead of waiting until equipment breaks down to perform repairs, TPM emphasizes a proactive maintenance approach.
Na TPM, todos os empregados são responsáveis e estão profundamente familiarizados com as máquinas e equipamentos com que trabalham. A manutenção já não é o papel de algumas pessoas no departamento; em vez disso, toda a equipa trabalha para completar as tarefas de manutenção preventiva.
Cada trabalhador ou operador da fábrica recebe a formação e a responsabilidade de gerir eficazmente o equipamento que utiliza. Os membros da equipa realizam a manutenção regular, como lubrificação, inspeção e pequenas reparações, assegurando a boa manutenção do equipamento. Isto liberta o pessoal de manutenção qualificado para efetuar reparações mais profundas, quando necessário.
Com uma estratégia TPM, cada membro da equipa familiariza-se completamente com a sua máquina e com o seu funcionamento. Se uma máquina tiver um problema, as pessoas que trabalham com ela diariamente têm o poder de se aperceber e de agir. Ou eles próprios resolvem o problema ou notificam a pessoa adequada para que o problema possa ser resolvido o mais rapidamente possível.
Total productive maintenance succeeds when everyone is involved and committed, but it also depends on clear processes and shared standards across the organization.
O que é o 5S na Manutenção Produtiva Total?
O 5S é um método sistemático utilizado na Manutenção Produtiva Total (TPM) para organizar e gerir o local de trabalho. O seu objetivo é criar um ambiente limpo, eficiente e seguro, centrando-se em cinco princípios fundamentais: Ordenar, Colocar em Ordem, Brilhar, Padronizar e Sustentar. Estes princípios ajudam a melhorar a produtividade, a reduzir o desperdício e a aumentar a eficiência operacional global.
1. Ordenar (Seiri):
- Esta etapa envolve a identificação e a remoção de objectos desnecessários do local de trabalho. Ao fazer uma triagem das ferramentas, equipamento e materiais, os trabalhadores podem eliminar a desordem e libertar espaço.
- Benefits: Reduces the risk of accidents, improves efficiency, and creates a more organized work area.
2. Colocar em ordem (Seiton):
- Organize os itens necessários numa ordem lógica para que sejam fáceis de aceder e utilizar. Isto envolve etiquetar e organizar ferramentas e materiais de forma a minimizar o desperdício de movimento e tempo.
- Benefits: Enhances workflow efficiency, reduces time spent searching for items, and creates a more orderly environment.
3. Brilho (Seiso):
- Limpe regularmente o local de trabalho e o equipamento para manter um ambiente arrumado e higiénico. Esta etapa implica uma limpeza e uma inspeção de rotina para garantir que tudo está em boas condições de funcionamento.
- Benefits: Prevents equipment deterioration, identifies potential issues early, and promotes a sense of pride and ownership among workers.
4. Padronizar (Seiketsu):
- Estabelecer procedimentos e práticas padronizados para manter as três primeiras etapas. Isto implica a criação de calendários, listas de controlo e directrizes para garantir a consistência e a sustentabilidade.
- Benefits: Ensures uniformity in workplace organization, reduces variability, and makes it easier to train new employees.
5. Sustentar (Shitsuke):
- Manter e melhorar continuamente as práticas dos 5S, promovendo uma cultura de disciplina e de melhoria contínua. Esta etapa envolve auditorias regulares, feedback e reforço dos princípios dos 5S.
- Benefits: Encourages ongoing adherence to best practices, promotes continuous improvement, and helps sustain the gains achieved through the 5S process.
A incorporação dos 5S na Manutenção Produtiva Total ajuda a criar um local de trabalho bem organizado, eficiente e seguro. Ao implementar sistematicamente estes princípios, as organizações podem aumentar a produtividade, reduzir o desperdício e apoiar uma cultura de melhoria contínua.
O que são os 8 Pilares da Manutenção Produtiva Total?
There are eight types of maintenance central to a complete and effective TPM strategy. These are known as the the eight pillars of TPM.
Segue-se uma descrição de cada um:
1. Manutenção autónoma
Os operadores recebem formação sobre procedimentos de rotina, desde a inspecção até às máquinas de lubrificação, assegurando que têm pleno conhecimento das competências técnicas necessárias para trabalhar com equipamento e solucionar problemas emergentes.
Example: Machine operators at a manufacturing plant are trained to perform daily cleaning, lubrication, and visual inspections on their machines. By doing so, they can quickly identify and report any unusual conditions, such as leaks or abnormal noises, to the maintenance team for further investigation and repair.
2. Manutenção da qualidade
Para efeitos de garantia de qualidade, é efectuada uma análise da causa principal para detetar as causas dos defeitos de qualidade. Os erros de conceção são detectados nesta fase e são tomadas medidas para evitar que os defeitos se desloquem a jusante e aumentem os custos.
Example: A food processing company implements a stringent quality maintenance program where equipment is regularly inspected for cleanliness and proper functioning. This prevents contamination and ensures that all products meet the required health and safety standards, thereby reducing customer complaints and product recalls.
3. Manutenção Planeada
Unlike other maintenance strategies, like Run to Failure (RTF) maintenance, a TPM strategy encourages preventive and proactive maintenance. These maintenance tasks can be scheduled when assets are idle, so rpoduction won’t be impacted as much.
Example: An automotive factory uses historical data to schedule regular maintenance activities for its assembly line robots. These activities include replacing worn-out parts and performing system diagnostics, which helps prevent unexpected breakdowns and keeps production running smoothly.
4. Melhoria focalizada
As equipas mais pequenas são convidadas a observar um processo específico e a planear formas de o melhorar. Esta atividade multifuncional permite-lhes reconhecer problemas persistentes na linha de montagem ou de produção, analisando simultaneamente os riscos de cada ação.
Example: A packaging facility forms a cross-functional team to address frequent bottlenecks in their production line. Through root cause analysis and brainstorming sessions, they implement process changes that increase throughput by 15% and reduce downtime.
5. Gestão precoce do equipamento
This pillar employs manufacturing practices via TPM to perfect new equipment designs, allowing them to meet ideal performance levels faster. As a result, maintenance is easier to manage and new machines can be installed at a lower cost.
Example: During the design phase of a new bottling line, the engineering team collaborates with maintenance technicians to ensure easy access to critical components. This collaboration results in a layout that simplifies maintenance tasks and reduces the time needed for equipment servicing.
6. Formação e Educação
A formação de operadores e gestores dá ao pessoal um novo conhecimento do TPM e das suas técnicas de manutenção preventiva. Os operadores aprendem a identificar e a gerir os problemas à medida que estes se desenvolvem. Os funcionários também podem receber coaching e desenvolvimento de carreira à parte.
Example: A chemical plant invests in a comprehensive training program for its employees, covering safe handling of materials, equipment operation, and emergency procedures. Regular refresher courses ensure that staff remain knowledgeable and capable of maintaining high safety and operational standards.
7. Segurança, Saúde e Ambiente
These considerations are meant to eliminate the risks of physical harm, ensuring an accident-free workplace where equipment is calibrated and correctly set up to align with safety standards.
Example: A mining company implements rigorous safety checks and regular maintenance on its heavy machinery. By doing so, they prevent hazardous equipment failures, protect their workers from accidents, and minimize environmental impacts from potential spills or emissions.
8. TPM na Administração
This pillar seeks to reduce administrative waste in areas such as procurement, scheduling, and order approval by applying TPM principles to streamline tasks such as locating spare parts and delivering production materials.
Example: A manufacturing plant realized that delays in maintenance were often caused by a lack of readily available spare parts. Technicians spent too much time chasing down part numbers, waiting on procurement, or discovering that the wrong items had been ordered. To address this, the administrative and maintenance teams collaborated to create a standardized digital parts catalog linked to each machine and implement a reorder alert system for critical spares based on usage rates. This streamlined the parts reordering and ensured critical spares were always available and easy to locate.
TPM can be calculated from tangible maintenance key performance indicators (KPIs) such as Overall Equipment Effectiveness (OEE). This measures the efficiency, availability, and quality of assets required for mass production. Any equipment performing under peak capacity, stopped in the middle of production, or producing lower-quality output will reduce the OEE score.
Benefícios da Manutenção Produtiva Total
The benefits of total productive maintenance start at the production floor and move all the way to the administrative offices and the end users of your product.
1. Reduced Downtime
O TPM reduz ou mesmo elimina o tempo de inatividade, assegurando que todos os activos estão a funcionar na sua capacidade máxima com resultados da mais alta qualidade. Isto assegura níveis de produção óptimos e produtos de alta qualidade, melhorando, em última análise, o resultado final e a satisfação do cliente.
2. Improved Equipment Availability
The practice of getting employees involved in maintaining and taking responsibility for their own equipment means failures are caught sooner, ensuring assets will be more available and function more smoothly.
3. Safer Working Environment
TPM practices help ensure a safer working environment by encouraging employees to keep their stations clean and well-organized, so that equipment issues are easy to spot before they escalate into bigger, more dangerous problems.
4. Employee Growth
As práticas de manutenção TPM permitem que os funcionários tenham mais propriedade e autonomia e se tornem mais completos e melhor formados à medida que adquirem mais conhecimentos sobre o equipamento com que estão a trabalhar. Também encoraja a resolução de problemas e a criatividade, bem como a partilha de conhecimentos e o trabalho de equipa entre departamentos.
5. Reduced Maintenance Costs
TPM encourages proactive, operator-led maintenance that catches small issues before they become expensive breakdowns. By reducing unplanned downtime and extending the time between major repairs, maintenance costs drop significantly over time.
6. Longer Equipment Lifespan
Through regular inspections, cleaning, and early problem detection, TPM helps keep equipment in optimal condition. This not only improves performance but also extends the useful life of machines by preventing wear and tear from going unnoticed.
7. Improved OEE Score
TPM boosts Overall Equipment Effectiveness by minimizing downtime, speeding up changeovers, and reducing defects. With operators and maintenance teams working together, equipment runs more reliably, producing more high-quality output in less time.
Como um CMMS permite uma Estratégia de Manutenção Produtiva Total
O TPM é acompanhado por métricas de desempenho que ajudam os fabricantes a lidar com diferentes tipos de perda de produtividade. Para melhor visualizar o OEE e as suas categorias de perda, as equipas de manutenção podem empregar um software de sistema de gestão de manutenção computorizado (CMMS) para ajudar nas funções principais de cada passo do TPM. Por exemplo, um CMMS fornece a criação e o controlo automatizados de ordens de trabalho, facilitando a visualização do desempenho e a realização de ajustes, poupando um esforço manual significativo.
A CMMS combined with condition monitoring sensors can also show where and when assets are demonstrating signs of wear so that the team can restore them to normal conditions before they fail, allowing companies to enable predictive maintenance. Managers can even assign training workshops to employees through their CMMS accounts, including resources offered by vendors. Additionally, a CMMS generates repair logs during early equipment management, which are critical for uncovering the symptoms of asset failure.
A CMMS can strengthen quality assurance by supporting manual spot checks, integrating with condition-monitoring sensors, and helping identify patterns of energy or material waste that may indicate quality issues.
It reminds technicians to complete tasks like quality testing the final product. A CMMS can print safety inspections and audit records for further review, including identifying potential hazards such as components stored in flammable areas. Users can quickly retrieve standard operating procedures, certifications, and other checklists for external agencies.
Businesses that depend on machines to keep industrial processes moving face higher downtime costs when equipment isn’t working correctly. Fortunately, a Total Productive Maintenance (TPM) program helps address this by focusing on proactive and preventive maintenance to keep systems running smoothly and minimize losses.
Saiba mais sobre como um CMMS permite o TPM.
5 Passos para Começar com uma Estratégia TPM
Depois de ter uma boa compreensão do sistema 5S, está pronto para implementar um programa TPM. Esta secção irá mostrar-lhe como fazê-lo em cinco passos:
1. Identificar e Escolher Equipamento para a Área Piloto
Nesta etapa, o equipamento será selecionado de entre três categorias distintas:
- Mais fácil de melhorar
- Constrangimento/gargalo
- Mais problemático
Há prós e contras a ter em conta ao escolher um projeto inicial. As empresas que não têm experiência em manutenção produtiva total devem escolher um projeto da categoria mais fácil de melhorar para um sucesso mais rápido. Embora estes projectos possam não ter o maior impacto na sua organização, eles irão ajudá-lo a ganhar experiência no desenvolvimento e implementação de uma estratégia TPM. Estes projectos terão também uma elevada probabilidade de sucesso.
O nível seguinte é o dos projectos de constrangimento/gargalo, que aumentam a produção total e proporcionam um amplo retorno. Estes problemas são geralmente mais difíceis de resolver, mas também proporcionarão maiores benefícios do que os da categoria mais fácil de melhorar.
Por último, os projectos mais problemáticos dizem respeito a problemas bem conhecidos, a fim de reforçar uma estratégia de TPM. Embora estes projectos possam ter um grande impacto se forem bem sucedidos, podem ser difíceis de resolver.
2. Restaurar os bens à condição de funcionamento principal
Limpar a área circundante e tirar fotografias do equipamento para documentar o seu estado inicial. Este é o primeiro passo para o lançamento de um programa de manutenção autónomo para que os operadores e os técnicos estejam em sintonia sobre os procedimentos de limpeza e reparação de rotina.
Next, identify and document wear points and critical inspection areas. Use transparent guarding where possible to make visual checks easier, and label settings to streamline future audits. Take note of all lubrication points during a changeover to ensure nothing gets missed. Once everything is clearly documented, train operators on the required tasks and provide a checklist to guide their daily, weekly, and monthly responsibilities.
3. Medir os dados do OEE para compreender as principais perdas
Use smart sensors or connected devices to automatically capture the data needed for calculating Overall Equipment Effectiveness (OEE). This includes availability, performance, and quality metrics. By automating these calculations, you reduce manual errors and get real-time visibility into equipment performance.
Pay close attention to unplanned stop time. These unexpected interruptions often contribute the most to lost productivity. Identify the most frequent or time-consuming stop events and rank them from greatest to least impact.
Track this data consistently for at least two weeks to get a clear picture of where your biggest losses are happening. This will help you measure the effectiveness of your TPM efforts and prioritize the issues that will deliver the most value when resolved.
4. Responder às mudanças nas Seis Grandes Perdas
A origem do tempo produtivo perdido pode ser identificada através da introdução de uma abordagem de melhoria orientada. As seis principais perdas dividem-se nas seguintes categorias:
- Falha de equipamento
- Colocação em funcionamento e regulação
- Marcha lenta ou outras paragens menores
- Velocidade reduzida
- Defeitos de processo
- Redução do rendimento
Address the biggest loss through root cause analysis and appoint a cross-functional team to observe the remaining issues. Collect physical evidence of the symptoms, then record them on an Ishikawa diagram . The Ishikawa diagram, also known as a fishbone diagram or cause-and-effect diagram, will help identify root causes and effects of the problem. The proposed fixes should be put into motion by scheduling planned downtime. After repairs, reset production to see how effective the procedures are.
5. Integrar técnicas de manutenção pró-activa
Focus your proactive maintenance efforts on components that are prone to wear or failure. These may include bearings, belts, motors, or any parts subject to friction, heat, or repetitive motion. To identify potential failure points, consider running diagnostics like vibration analysis or thermal imaging to detect early signs of stress.
Once you’ve identified critical components, define maintenance intervals based on wear levels, predicted failure points, operating hours, or historical work order data. Set an initial baseline for each interval, then create a feedback loop using log sheets, condition monitoring data, and technician notes to fine-tune your schedule over time.
To keep the process effective, conduct monthly audits to verify the accuracy of maintenance records and ensure any new issues or observations are being properly logged and reviewed.
How to Achieve TPM with a CMMS
Atingir a TPM perfeita é um objetivo grandioso que pode nunca ser totalmente alcançado. No entanto, aderir aos princípios 5S e implementar os oito pilares da manutenção produtiva total coloca as organizações no caminho para chegar muito mais perto do TPM.
TPM tools like eMaint CMMS can encourage the process by providing data and metrics and reducing manual data gathering while supporting maintenance improvements. Combining a CMMS with tools such as vibration and temperature monitors supports the TPM maintenance process and empowers employees with even more ways to identify and correct maintenance issues before they cause unplanned downtime.
Here’s how a CMMS can help with each of the 8 pillars:
- Autonomous Maintenance
A CMMS allows each task or work order to be categorized in many ways, including who it needs to be assigned to. Depending on the skill required to complete the job, it can be assigned accordingly in a CMMS, with less complex tasks assigned to operators while more complex tasks can be assigned to technicians with the correct training and experience levels. - Qualilty Maintenance
While a PM schedule is required to ensure that quality is maintained through routine manual inspections, it may not be enough as there is still room for human error. It must then be reinforced by a predictive maintenance strategy deployed within the CMMS. Real-time monitoring sensors can detect potential problems before they occur and trigger the intervention of a maintenance technician before a defect or breakdown occurs. - Planned Maintenance
By tracking trends, analyzing real-time asset data, and following manufacturer recommendations, organizations can prevent production waste, shorter equipment life cycles, increased equipment replacement and labor costs, and unplanned downtime. A CMMS enables users to plan, set up and track these jobs. - Focused Improvement
A CMMS provides the historical data required to analyze failures on assets to find root cause of the failure. This will enable the technicians to gather knowledge on how each machine tends to break down. This information also allows maintenance teams to make modifications to assets or processes to ultimately improve reliability. - Early Equipment Management
Having complete historical data of an asset stored and available in a CMMS facilitates this pillar of TPM. The company can review breakdown causes and repairs. Consistent problems will be highlighted, and more permanent fixes can be made, from using a redesigned asset or making a change in the process of the maintenance schedule. - Education and Training
A CMMS can track training or certifications that may be required to complete a job. Alerts and notifications can be set up to see when training may be expired or if it is a requirement to complete a task. - Safety, Health, and Environment
A CMMS allows companies to store information such as safety data sheets, standard operating procedures, and safety checklists. If required by auditors, the reporting feature in a CMMS will demonstrate that safety requirements have been followed. - TPM in Administration
A CMMS can help bridge the gap between maintenance and administration personnel. Both are required to run a successful manufacturing operation, but rarely work side-by-side. A CMMS can act as a single source of truth for both groups. It provides easy access to documentation such as photos and operating manuals, reducing time searching for these documents. Admin staff can also leverage inventory and spare parts tracking in a CMMS to ensure parts are available for maintenance teams.
Estabelecer metas e objectivos claros enquanto se promove uma cultura de melhoria contínua permitirá à sua organização atingir marcos chave de TPM com o tempo. À medida que trabalha continuamente na sua estratégia TPM, estará perto de atingir o objetivo final: sem avarias, defeitos de produto, paragens não planeadas, abrandamentos ou incidentes de segurança.