Reduces cost by catching defects early (it is expensive and unreliable to find defects through inspection). Specifically targets quality issues with improvement projects focused on removing root sources of defects. Apply Root Cause Analysis to eliminate recurring sources of quality defects. Reduces inventory through better control of wear-prone and failure-prone parts.ĭesign error detection and prevention into production processes. Enables most maintenance to be planned for times when equipment is not scheduled for production. Significantly reduces instances of unplanned stop time. Schedules maintenance tasks based on predicted and/or measured failure rates. Frees maintenance personnel for higher-level tasks. Identifies emergent issues before they become failures. Ensures equipment is well-cleaned and lubricated. Increases operators’ knowledge of their equipment. Gives operators greater “ownership” of their equipment. Places responsibility for routine maintenance, such as cleaning, lubricating, and inspection, in the hands of operators. The eight pillars of TPM are mostly focused on proactive and preventative techniques for improving equipment reliability. For example, in a clean and well-organized work environment, tools and parts are much easier to find, and it is much easier to spot emerging issues such as fluid leaks, material spills, metal shavings from unexpected wear, hairline cracks in mechanisms, etc. It should be reasonably intuitive how 5S creates a foundation for well-running equipment. Sustain: ensure the standards are regularly applied. Standardize: create standards for performing the above three activities. Straighten: organize the remaining items. Sort: eliminate anything that is not truly needed in the work area. 
The goal of 5S is to create a work environment that is clean and well-organized. The traditional TPM model consists of a 5S foundation (Sort, Set in Order, Shine, Standardize, and Sustain) and eight supporting pillars.
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