TPM Workflow Management Software
Total Productive Maintenance
Total Productive Maintenance (TPM) is a holistic approach to equipment maintenance that emphasizes prevention to maximize Overall Equipment Effectiveness (OEE) and Operational Excellence. The goal of TPM is zero breakdowns, zero product defects and zero safety incidents. The methodology emphasizes autonomous, operator-led routine machine maintenance, as well as proactive and preventive maintenance to maximize the lifespan and productivity of equipment.
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tpm pillar 1
Focused Improvement
Focused improvement is the first pillar of TPM. The priorities are clear: improve, improve, and improve continuously. To avoid the loss of equipment, talent, raw materials, and energy, the whole team must share this vision. The team must be proactive, willing to try new methods, and eager to sit around the table to work out problems.
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Gemba Walks
Ensure Gemba Walks are completed correctly including photos or video capture.
Kaizen
Digitize Kaizen workflows and promote continuous improvement from small, ongoing, incremental positive changes.
Suggestions
Capture and act upon employee suggestions to reduce losses and waste.
Root Cause Analysis (RCA)
Uncover one or many root causes for a given abnormality.
tpm pillar 2
Autonomous Maintenance
Autonomous Maintenance (AM) is the first and most important pillar in TPM because by offloading basic maintenance tasks to operators. maintenance teams have the time and resources to tackle everything else. AM provides operators with the skills, training and autonomy to clean, inspect, and contribute to the upkeep of the assets they work with. This ensures every piece of equipment is cared for, improves early fault detection, significantly increases operator engagement and retention, and frees maintenance technicians for heavier tasks.
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SQDCP Board
Digitize SQDCP (Safety, Quality, Delivery, Cost, and People) Boards and Supercharge Performance
5S Workstation Optimization
Ensure workstations are optimized correctly and improvements are sustained by documenting Sort, Set in Order and Shine steps including photos and videos.
Clean, Inspect, Lubricate (CIL)
Provide instructions and capture valuable data in real-time. Make it easy and ensure compliance.
Centerline Audits
Create a schedule and provide instructions to ensure compliance.
5S Auditing
Ensure 5S audits are completed correctly including photos or video capture.
Abnormality Reporting
Make it easy for staff to report Process Abnormalities and for managers to initiate PDCA projects.
Ultimate Guide to Success with Autonomous Maintenance
Everything you need to know about how Autonomous Maintenance works and the best practices gleaned from our 10+ years of experience helping organizations achieve success.
Everything you need to know about how Autonomous Maintenance works and the best practices gleaned from our 10+ years of experience helping organizations achieve success.
tpm pillar 3
Quality Maintenance
One of TPM’s biggest goals is manufacturing zero defective products, which, undoubtedly, also plays into customer satisfaction. Hence, quality management and implementing internal processes linked to quality control are another pillar. We recommend several root cause analysis tools to root out problems. Performing maintenance actions for the equipment's care, so that it does not generate quality defects, certifying that the machinery meets the basic conditions for "zero breakdowns" and that this equipment is within the technical standards.
EXPLORE WEEVER SOLUTIONS
Quality Assurance Matrix
Understand and prevent quality defects within the context of Total Productive Maintenance (TPM).
Root Cause Analysis (RCA)
Uncover one or many root causes for a given abnormality.
tpm pillar 4
Planned Maintenance
Planned Maintenance, also called Preventive or Predictive, involves monitoring the state of deterioration of production machines and equipment so maintenance teams can act in advance of breakdowns to ensure lines continue to run as planned. Preventive maintenance is almost always less expensive and less disruptive than breakdown maintenance.
Autonomous Maintenance (AM) is essential to Planned Maintenance for a variety of reasons. AM ensures machines are cleaned, centerlined and lubricated regularly, ensuring optimal operating conditions. AM requires regular part and component inspections, which is paramount for predictive analysis. Finally, AM saves maintenance teams time and resources that can be reallocated to support planned maintenance initiatives.
EXPLORE WEEVER SOLUTIONS
Machine Ledger
Understand when and why parts breakdown so you can predict failures and prevent unplanned stoppages.
Planned Maintenance Schedules
Create and manage planned maintenance schedules for machines and equipment.
Root Cause Analysis (RCA)
Uncover one or many root causes for a given abnormality.
tpm pillar 5
Early Equipment Management
Early Equipment Management (EEM) is a structured process that reduces the complexity of operations and maintenance through optimal design, engineering, procurement and installation of machines and equipment. When it’s time to choose new equipment or develop new products, consider previous experiences to make maintenance easier. This can be as simple as choosing a washable paint for the walls (which makes cleaning easier), or as complex as picking a robot which can self-diagnose malfunctions (which improves production).
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Early Equipment Management Checklist
Stay on top of your Early Equipment Management projects and ensure compliance.
tpm pillar 6
Training and Education
Companies progress by developing their employees’ capabilities and maximizing their ability to work effectively. TPM requires investing in training and education so employees have the skills, knowledge, tools and resources they need to deliver successful outcomes. This includes knowledge associated with their specific job, but also a basic understanding of other things like safety, quality and machine maintenance. The first step in Training and Education is understanding the skills of your employees and the gaps that need to be filled.
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Employee Recertification Tracker
Never forget a recertification date.
tpm pillar 7
Safety, Health and Environment
The Safety, Health and Environment (SHE) Pillar is the cornerstone TPM Pillar that supports and lends stability to the overall continuous improvement process and all of the other TPM Pillars. The goal of the SHE pillar is zero work accidents, zero pollution, and zero burnout. The SHE pillar emphasizes autonomous safety where everyone is responsible for their own safety and the safety of others. Good maintenance management not only avoids accidents during maintenance activities but also contributes to every worker’s well-being and safety.
EXPLORE WEEVER SOLUTIONS
Shift Report
Comprehensive shift-to-shift reporting on production, safety, quality, maintenance, etc.
Lockout Tagout (LOTO)
Ensure your LOTO processes are adhered to for each machine.
Work Permits
Ensure compliance processes for all work permits.
Incident & Near Miss
Accessible and customizable template to capture what you need to initiate and manage investigations.
Root Cause Analysis (RCA)
Uncover one or many root causes for a given abnormality.
tpm pillar 8
Office TPM
The last of the 8 pillars is office TPM. This means administrative workers and managers should also chip in, instead of leaving it to the “worker bees”. Everyone, without exception, must be proactive and focused on improvements, from logistics to scheduling.
EXPLORE WEEVER SOLUTIONS
SQDCP Board
Digitize SQDCP (Safety, Quality, Delivery, Cost, and People) Boards and Supercharge Performance
5S Workstation Optimization
Ensure workstations are optimized correctly and improvements are sustained by documenting Sort, Set in Order and Shine steps including photos and videos.
Gemba Walks
Ensure Gemba Walks are completed correctly including photos or video capture.
Employee Recertification Tracker
Never forget a recertification date.
5S Auditing
Ensure 5S audits are completed correctly including photos or video capture.
Root Cause Analysis (RCA)
Uncover one or many root causes for a given abnormality.
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