TPM improvement starts with a consistent loss model.
- Current OEE per line
- Availability, performance, and quality breakdowns
- Six-big-losses analysis
- Target setting and trend views
TPM 8 feature areas
Total Productive Maintenance.
Operator-driven reliability. Autonomous maintenance, OEE, and the eight pillars in practice.
Operators own daily care, abnormality capture, and first-response routines.
- Cleaning, inspection, and lubrication standards
- Mobile operator checklists
- Photo abnormality reporting
- Tag system for follow-up work
Kaizen work ties directly to measured operational losses.
- A3 problem-solving records
- Idea and improvement register
- Savings and loss-reduction tracking
- Recognition workflows for completed improvements
TPM routines coordinate with EAM work orders and the production plan.
- Preventive maintenance schedule view
- Due and overdue indicators
- Operator-maintenance handoff
- Planned versus unplanned work tracking
Reliability requirements can be captured before new equipment goes live.
- Commissioning checklists
- Lifecycle cost inputs
- Reliability targets at design
- Lessons-learned capture for future equipment
TPM only scales when people are qualified for the routines they own.
- Operator skills matrix
- Training requirements by asset or task
- Qualification expiry alerts
- Standard-work acknowledgement
Safety, cleanup, and environmental checks fit into daily maintenance habits.
- Safety inspection items on checklists
- Lockout and verification prompts
- Leak, spill, and abnormality capture
- Escalation paths for high-risk findings
Losses are categorized so improvement work can be prioritized.
- Downtime reason trees
- Minor stoppage tracking
- Defect and startup-loss categories
- Pareto analysis by line, asset, and product
TPM FAQ
Total Productive Maintenance — questions buyers actually ask.
What does NexliOne TPM cover beyond traditional maintenance software?
NexliOne TPM is built around the eight pillars of Total Productive Maintenance — operator-led autonomous maintenance (CIL standards, mobile checklists, tag system), focused improvement Kaizen, early equipment management, and OEE tracking. It complements EAM by putting reliability work in the hands of the operators closest to the equipment.
Does NexliOne TPM track OEE current across multiple lines?
NexliOne is designed to support this workflow. Current OEE per line is broken down by Availability, Performance, and Quality, with six-big-losses analysis, shift comparison, target setting, and drill-through to the underlying events. The same OEE data is shared with the Manufacturing module so MES and TPM see one number.
How does NexliOne TPM enable operator-led autonomous maintenance?
Operators run cleaning, inspection, and lubrication (CIL) standards via mobile checklists, with photo abnormality reporting and a tag system for issues that need maintenance follow-up. An operator skills matrix tracks which tasks each operator is qualified to perform.
Can NexliOne TPM support Kaizen events and A3 problem solving?
NexliOne is designed to support this workflow. Focused-improvement projects use A3 problem solving, an idea register, savings calculations, and recognition workflows. Project tracking ties each Kaizen to the OEE losses it targets so improvement work is measured against the loss it addresses.
How does NexliOne TPM differ from EAM, and do I need both?
EAM is the maintenance system of record — assets, work orders, spares, PM/PdM. TPM is the operator-driven reliability layer — autonomous maintenance, OEE, Kaizen, early equipment management. They share the asset registry and work-order infrastructure, so running both gives you the technician layer and the operator layer working from the same data.
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