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TPM management, namely “Total Productive Maintenance,” originated in Japan in the 1970s. It is a production maintenance approach that involves all employees, with its key aspects being “production maintenance” and “full employee participation.” Optimize equipment performance by establishing a system-wide production and maintenance activity involving all employees. When the dimensions, shape, or material of a certain structure, mechanism, or component in a device changes, preventing it from performing its intended functions properly, this is referred to as a device failure. When a device malfunctions, it can affect factors such as product quality, production efficiency, and operational suitability; it may also reduce the device’s accuracy and lifespan ； In severe cases, it can lead to major incidents such as production shutdowns, environmental pollution, safety accidents, and personal injuries. Therefore, on-site managers should pay attention to preventing equipment failures. I. Analysis of the causes of TPM equipment failures 1. Design flaws Design flaws include structural defects, improper selection of materials, insufficient strength, lack of safety devices, and inappropriate choice of components. 2. Manufacturing and processing defects Manufacturing and processing defects include inaccurate dimensions, insufficient machining precision, unbalanced movement of components, and combinations of parts whose various functions are reduced. 3. Installation defects Installation defects include incorrect part configuration, presence of foreign objects, improper adjustment of mechanical and electrical components, missing parts, oil leakage in the hydraulic system, unstable fixation of the frame, uneven mechanical installation, and incorrect adjustments. 4. Defects in quality management Defects in quality management include failing to manufacture and inspect products in accordance with quality standards, using substandard parts and components, employing malfunctioning control devices, and omitting inspection items. 5. Operational defects Operational defects include environmental loads exceeding specified values, operating conditions exceeding prescribed limits, misoperations or violations of operating procedures, components and parts being used beyond their designed lifespan, lack of lubrication, wear and tear on components, equipment corrosion, and loose components during operation. 6. Repair defects Repair defects include failure to carry out repairs as required, poor quality of repairs, failure to replace worn-out parts, inability to identify the location of faults, and allowing the equipment to operate while damaged. II. Key Points for Preventing Failures in TPM Field Equipment There are mainly two approaches to preventing failures in equipment used in industrial production sites: 1. Prevention during equipment use ① Consult the manufacturer’s instructions for using the equipment to understand the standard methods of operation. ②Learn from the manufacturer the key points of maintenance and inspection, as well as the procedures to take in case of failures. ③Ask about the method of notifying the manufacturer when there is a problem with the equipment. ④Prepare the materials and items required for maintenance (a certain quantity can be stocked). 2. Prevention during normal operation ① Follow the operating procedures, and identify minor defects in the equipment through thorough cleaning. ②Conduct daily inspections of the equipment using the prescribed routine inspection checklist, and address any abnormalities found by following the operation manual. ③If you cannot repair it yourself, notify the manufacturer immediately. ④All abnormal phenomena during operation must be reported to the direct supervisor. When the technical condition of equipment deteriorates or it malfunctions, in order to restore its functionality and accuracy, companies should inspect the equipment, either partially or as a whole, and select an appropriate repair method to bring it back to normal operating conditions.