In a manufacturing plant, the production schedule and targets to be achieved are set before operating the machine. What would happen if a machine suddenly breaks down? The schedule would be affected and operator’s time would be wasted till the equipment is fixed. That would increase the cycle time effectively.

The time required to fix the machine is uncertain and maintenance staff might take too long to bring it back to working condition in certain cases. In such situations of equipment breakdown, the operator has nothing to do and cannot achieve the target at any cost because of the lost time.

As it is an unplanned scenario, extra costs are incurred by the organization for lower production than planned. Breakdown of equipment resembles a problem that should have been solved before it happened. TPM supports the reduction of unplanned breakdown of machines and keeps it in good health for smooth operation.

By minimizing equipment breakdown, on-time and good quality production is ensured. If the organization has a planned operating structure and means to tackle breakdowns, the operators would be able to complete the job on time.