AQMS || Transforming Business

What is TPM

A company-wide system to eliminate every factory loss

TPM (Total Productive Maintenance) is a comprehensive, company-wide management system. It aims to eliminate all factory losses — targeting zero breakdowns, zero defects and zero accidents — by engaging every employee, from the shop floor to senior management, in small-group, proactive activities.

With its 8 pillars, TPM ensures total employee involvement and participation of all functions in improving equipment and plant effectiveness, thereby improving the PQCDSME index of the organisation.

AQMS consultants carry 25+ years of TPM implementation experience and have supported 45+ companies.

Total Productive Maintenance implementation at a manufacturing plant

Core Meaning

What "Total" actually means in TPM

JIPM defines the word "Total" through three distinct dimensions.

Total Effectiveness

Economic efficiency and profitability of the operation as a whole.

Total Maintenance System

Prevention, maintenance and reliability engineering across the entire life cycle of the equipment.

Total Participation

Involvement of all employees — operators, maintenance technicians and administrative staff alike.

The Framework

The Eight Pillars of TPM

JIPM structures TPM around eight foundational activity areas.

Focused Improvement
(Kobetsu Kaizen)

Small teams systematically target and eliminate major equipment losses.

Autonomous Maintenance
(Jishu Hozen)

Operators clean, inspect and lubricate their own machines.

Planned Maintenance

Scheduling proactive tasks based on machine data and wear trends.

Quality Maintenance

Designing error-prevention steps into processes to stop defects at source.

Early Equipment Management

Using past lessons to design better, easy-to-maintain new equipment.

Training and Education

Upgrading technical and operational skills for all workers.

Safety, Health and Environment

Maintaining a hazard-free, clean workspace.

Office / Administrative TPM

Applying efficiency concepts to support and logistics departments.

Why TPM

Why TPM belongs in your organisation

Globally, TPM practices have been widely accepted and, since their inception, a majority of companies have adopted TPM.

TPM maximises equipment efficiency, minimises unexpected downtime and engages every worker in proactive care. It transforms equipment maintenance from a reactive chore into a shared organisational strategy.

Cumulative trend of TPM award-winning companies and awards in India from 1995 to 2025 — 352 companies and 564 awards — Cumulative trends of companies and awards in India, 1995–2025. Source: JIPM award data.

It primarily targets the "four zeroes"

Zero breakdowns Zero defects Zero accidents Zero loss

4000+

TPM awards presented globally

352

Companies in India with the award

564

Indian plants that achieved it

Key Benefits

What TPM changes on the shop floor

Higher Productivity

Keeps machines running at peak speed and reduces cycle times.

Lower Costs

Stops expensive emergency repairs by fixing small issues early.

Better Product Quality

Reduces machine errors that cause product flaws.

Worker Empowerment

Trains machine operators to handle basic cleaning and routine checks themselves.

Safer Workplaces

Eliminates physical risks and lowers accident rates.

Sustained Discipline

Builds daily habits and small-group activity that keep gains from slipping back.

Expected Results

What you can expect by implementing TPM

Typical outcomes achieved by companies that implement TPM end to end.

50%

Cut in breakdowns

30%

Lower maintenance cost

30%

Reduction in defects

Zero

Accidents on the floor

OEE↑

Boost in overall equipment effectiveness

Want these numbers at your plant?

Get a no-obligation assessment call with an AQMS TPM consultant.

+91 93157 85620

Why AQMS

Your TPM consultancy partner

AQMS brings authentic, hands-on consulting experience to every TPM engagement:

Around 30 to 50 years of consulting experience
Over 100 manufacturing plants improved performance using TPM concepts
34 plants achieved JIPM awards
Complete transformation in shops including layout, equipment condition and more
Programs customised to each client's products and processes
Extensive handholding across all our services
In-depth cross-experience from ISO standards, MOST, Six Sigma and Lean manufacturing

AQMS TPM consultants supporting a client plant

Our Approach

AQMS approach for TPM implementation

Preparatory Stage

Execution Stage

Receipt of Award

Preparatory Stage Year 1

Program Launch
Business Objective
Manager Model Machine
Working on MMM

Execution Stage Year 2 TPM
Kick-Off

Launch of 8 Pillars
Policy deployment
Freezing KPI & KAI
Development of Data collection system for KPI and KAIs
Working on KK, JH, PM, E&T and SHE

Execution Stage Year 3

Continue working on 5 Pillars
Working on DM / QM / OTPM

Execution Stage Year 4

Improvement on the initiatives
Preparation of “Activity Report”
Health check-up for application
Application Filing

Receipt of Award Year 5

Support for assessment
Receipt of Award at JIPM, Japan

Monthly Review meeting by AQMS

Year - 1 Year - 2 Year - 3 Year - 4 Year - 5

12-step methodology

We follow a structured 12-step methodology for complete implementation.

Model machine / area programme

Development of the initial implementation program on a selected Manager Model Machine or Area (MMM/MMA).

Company-wide kick-off

Improving the MMM/MMA and kick-off for company-wide TPM implementation.

Policy deployment

Implementation of the Key Management Index (KMI) through KPIs and KAIs.

Master planning

Development of the overall master plan and pillar-wise master plans.

Training and handholding

Regular support, review, training and handholding to implement TPM in accordance with JIPM guidelines.

Award assessment support

Support in assessment preparation, including activity report development and the final assessment by JIPM for the TPM Award.

Typical duration: 3 – 5 years up to JIPM award

Free initial consultation

Start your TPM journey with a plant assessment

Talk to an AQMS consultant about a Manager Model Machine pilot and a roadmap built around your products, processes and shop-floor realities. We will walk you through what the first 90 days would look like at your plant.

+91 120 4288591 WhatsApp us Request a call back

45+ Companies supported

34 Plants won JIPM awards

25+ Years of TPM experience

Speak to us directly

+91 93157 85620 +91 120 4288591 reecha.sinha@aqms.in I-679, Gaur Grandeur, Sector 119, Noida, Uttar Pradesh 201301, India