Modern Total Productive Maintenance (TPM)

The factories that win the next decade will not be the ones with the most sensors.

1. They will be the ones where truth arrives early, closure is verified, and normal is defined so precisely that abnormal cannot hide.
2. That operating system is Total Productive Maintenance, and this book shows how to build it for a plant full of IoT, analytics, and AI.

Modern Total Productive Maintenance covers the classical foundations, including

• the Eight Pillars,
• the Six Big Losses,
• OEE,
• autonomous maintenance,
• planned maintenance,
• focused improvement,
• quality maintenance, and
• early equipment management,

and then shows how each one changes when the plant can see condition data in real time.

WHAT YOU WILL LEARN

- Where TPM came from and why it still works: Nakajima, the 1971 Denso award, and the three zeros of breakdowns, defects, and accidents.

- How to calculate OEE honestly, what the 85 percent world-class benchmark really means, and why it is meaningless unless two plants measure the same way.

- How to attack micro-stops, the losses too small to escalate that quietly drain performance every shift.

- Predictive versus prescriptive maintenance, and why a plant that cannot close a forecast will not be rescued by a system that writes the plan for it.

- Computer vision, digital twins, agentic AI, and tamper-evident records, each tied back to the TPM discipline it has to serve.

- A three-phase roadmap to TPM 4.0: stabilize, improve, and sustain, with the test that tells you whether the gains will survive the worst week of the year.

WRITTEN FOR THE PERSON WHO HAS TO MAKE IT WORK

• Reliability engineers,
• maintenance managers,
• plant and operations leaders,
• continuous-improvement specialists, and
• technicians moving into leadership.

Recurring examples, such as a sealing station and a bottleneck filler, run from chapter to chapter, so ideas build on each other instead of standing alone.

A 30-term dictionary sets out what each term means in this book.

LEARN IT, THEN PROVE IT. A free 20-lesson Modern TPM class and certificate exam accompany this book at Global Sovereign University, a tuition-free 501(c) (3) nonprofit funded by the sale of books like this one.