TPM Machine Classification in Manufacturing

What is TPM Classification?

Total Productive Maintenance (TPM) aims to maximize equipment effectiveness and eliminate breakdowns. One of the key steps in TPM is classifying your machines based on their criticality, to prioritize maintenance resources efficiently.

By evaluating various aspects like failure frequency, repair cost, and production impact, each machine is scored and categorized into segments (AA, A, B, C) that guide your action plans.

How the Scoring Works

Each machine is evaluated through 11 criteria. Each criterion is rated with a score of 1, 2, or 4 points depending on its severity or importance. The total score determines its priority level.

• 1 point: Low risk or impact
• 2 points: Medium
• 4 points: High risk or critical

Once the scores are calculated, they can be sorted, and maintenance can be planned starting from the highest scoring machines.

Classification Levels (AA / A / B / C)

After scoring, machines are categorized based on their total score percentile and corresponding maintenance strategy:

• AA Class: Top 7% of all machinery and equipment – Critical machines selected for TPM pilot introduction. Main target is zero interruption with a high level of foresighted maintenance. Continuous target monitoring is implemented.
• A Class: Next 25% – These machines form the second step towards zero-interruption and zero-quality failure. They require a medium level of foresighted maintenance, with continuous, easy, and detailed diagnosis.
• B Class: 60% – These machines follow preventive (time-based) maintenance. The aim is to keep interruptions and breakdowns low while balancing limited budget and manpower.
• C Class: Remaining 8% – Maintenance is reactive, based on actual breakdowns and troubles. This is typically the starting approach for these machines. Consider replacement or minimal investment unless upgraded.

This classification ensures maintenance resources are allocated strategically, with focus given to the most impactful equipment first.

🧮 Online TPM Score Calculator

Machine Name:

#	Criteria	Score (with description)