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Total productive maintenance software that keeps your TPM program going on the shop floor

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New to TPM? Read what TPM is and how the eight pillars work.

TPM software: the EZ-GO app on a tablet at the line

Total Productive Maintenance (TPM) is a program that involves everyone in the plant, from operator to plant manager, in keeping equipment in good condition. Its goal is zero breakdowns, zero defects, and zero accidents.

The EZ-GO platform supports the daily work behind the pillars at the line: autonomous maintenance tasks, step audits, defect follow-up, one-point lessons, and skills. Your teams spend their time on TPM itself, and you get the data without collecting it by hand.

Where TPM programs stall after the pilot line

Work on a FrieslandCampina production line

The pilot line usually goes well. The team reaches the first steps of autonomous maintenance, the activity board is up to date, and the steering group sees results. Then the program spreads to more lines, and the administration grows faster than the results.

Defect tags stay open, and nobody can see for how long. One-point lessons get made, but it is unclear who has learned them. Step audits take a day to prepare, and the results stay in a report that the line does not see. The TPM coordinator spends more time collecting data than coaching teams.

The method itself holds up. What makes programs stall is the daily work around the pillars, which is hard to keep up across shifts, lines, and sites.

How the EZ-GO platform supports each TPM pillar

Autonomous maintenance: from step 1 to a standard that holds

Operators get their cleaning, inspection, lubrication, and tightening tasks for each machine and shift in the EZ-GO app, with photos and videos of the right way. They report what they find with a photo, linked to the machine. You run the audit for each autonomous maintenance step in the app, with photo evidence, and the results show for each line where the standard holds and where it slips. 5S audits work the same way.

Safety, health and environment: safety checks that do not get skipped

Safety checks, such as guards, emergency stops, and lockout steps, become part of the daily round and of your audits. A lockout and tagout procedure can run as a digital checklist, so everyone follows the same steps before working on the machine. When an operator sees an unsafe situation, he reports it with a photo, and it becomes an action with an owner and a due date. Every check is recorded, so you can show what was done and when. More on safety on the shop floor.

Quality maintenance: connect equipment condition to product quality

Machine settings that affect quality, such as temperatures, pressures, or centerline values, are checked and recorded at fixed moments in a digital form, as part of a scheduled task. This is the core of centerlining: record the ideal setting for each parameter and keep the machine there. When a value is outside the limit, the operator turns it into an action right away. When a quality problem shows up later, the history per machine helps you find where it started. More on quality and hygiene.

Focused improvement: see which losses keep coming back

The standard reports in the EZ-GO app show the deviations that come back most often, per line and per machine. That gives your improvement teams a clear place to start, and the input for a Pareto analysis. Ideas from operators become actions with an owner, so they do not get lost between shifts. More on continuous improvement.

Planned maintenance: early signals for your technicians

Operators take over routine inspections and report defects early, with a photo and the exact machine. That gives technicians time back for planned work. When a technician finds the cause of a problem, he adds his comments to the action, so the operator can see what is going on. Repairs and replacements are usually planned in your maintenance system. If the EZ-GO platform is connected to that system, for example Ultimo, its status updates and comments are also visible in the EZ-GO app. If the shifts need to watch a machine for a while, someone with editing rights, such as a maintenance engineer, sets up a temporary inspection task. More on what changes for maintenance technicians.

Training and education: know who can do which task

One-point lessons and work instructions sit at the machine, with photos and short videos. The skills matrix shows who is qualified for which autonomous maintenance task, and you assess operators on what is in the instruction. New and temporary staff learn the standard on the job, from your own best operators. More on skills and onboarding.

Where the EZ-GO platform plays a smaller role

For early equipment management, the history of reports and actions per machine is useful input when you plan or buy new equipment. The platform does not manage the design or purchase process itself. Office TPM is not the focus of the EZ-GO platform either. Its strength is the work at the line.

An example from the line

On the late shift, an operator sees that a material roll on the packaging machine runs slightly crooked. Maintenance has already gone home. In the EZ-GO app, he finds a short video for this machine that shows how to place the roll correctly. Together with his team leader, he stops the machine, follows the video, and starts again. The stop is short, and nobody needs to call the on-call technician.

Because it is not the first time, he also reports it in the app with a photo. The next morning, a technician finds the cause: a worn ring that no longer holds the roll in place. He adds a task to order and replace the ring, and asks the shifts to watch this point until then. After the repair, a monthly check of the ring becomes part of the autonomous maintenance round.

This one small problem touches four pillars: autonomous maintenance, planned maintenance, focused improvement, and training. Read the full example and two other ways to reduce breakdowns.

Questions about total productive maintenance software

What is total productive maintenance (TPM) software?

Total productive maintenance (TPM) software supports the daily work of a TPM program on the shop floor: autonomous maintenance tasks, step audits, defect follow-up, one-point lessons, and skills. The EZ-GO platform is a connected worker platform that gives operators and team leaders this work on a tablet at the line, and gives the TPM coordinator an overview for each line and site.

Which TPM pillars does the EZ-GO platform support?

The EZ-GO platform supports autonomous maintenance, safety, quality maintenance, focused improvement, planned maintenance, and training, with tasks, checklists, audits, actions, work instructions, and a skills matrix. For early equipment management, it provides the history per machine as input. Office TPM is not its focus.

Can we keep our own TPM approach in the EZ-GO platform?

Yes. You build tasks, audits, instructions, and steps in the EZ-GO platform in your own format, so the platform follows your TPM program. Many teams use the start as a moment to improve their standards, instead of copying their current lists one-to-one.

Does the EZ-GO platform calculate OEE?

The EZ-GO platform records what happens at the line, such as tasks, checks, defects and actions, which helps you understand the losses behind your OEE figures. For the calculation itself, read how to calculate OEE.

How do we keep TPM going across more lines and sites?

Copy a standard that works on one line to similar lines, and compare lines and sites in one overview. The EZ-GO platform runs in the cloud, so every site works with the same version, and user rights and access per area decide who can see and edit what.

What is the difference between TPM and autonomous maintenance?

Autonomous maintenance is one of the pillars of TPM, and usually the first one a plant starts with. In autonomous maintenance, operators take care of the basic condition of their own machines. TPM is the full program around it, including safety, quality, planned maintenance, and training. Read more about autonomous maintenance.

Ready to see your TPM program at the line?

In a short demo, we show you how autonomous maintenance tasks, step audits, and defect reports come together in the EZ-GO app, built around your own pillars.

Schedule a demo See how autonomous maintenance works