TPM Software for Manufacturing: Run All Eight Pillars in One AI CMMS

TPM software

TPM software for all eight pillars

MaintWiz runs every pillar JIPM defines, on a 5S foundation, in one AI CMMS: autonomous maintenance (Jishu Hozen), focused improvement (Kobetsu Kaizen), planned maintenance, quality maintenance, education and training, safety, health and environment, early equipment management and office TPM. Kaizen, one point lessons, OEE and ePTW sit on the same equipment list, so work orders and every pillar's records stay together.

It connects to SAP PM and MM through web services (SAP integration). TPM software means a CMMS that runs all eight pillars on one equipment list, and MaintWiz TPM software gives each pillar its own module and dashboard. Pricing is quoted on request for the modules and users you need: get a quote or see how TPM software is priced.

TPM applies from steel and cement to pharma, food and automotive: see TPM by industry. It is practised worldwide: JIPM's archive lists 1,569 TPM award entries from 54 countries outside Japan for 2006 to 2025, and the award winners by country tables show where, with market pages for China, Thailand, Vietnam and Indonesia, Latin America and Turkey and Europe.

Digital TPM

What does digital TPM mean?

Digital TPM means running all eight pillars and the 5S foundation in one system instead of on paper and spreadsheets. Autonomous maintenance, focused improvement and Kaizen, planned maintenance, quality maintenance, education and training, safety, health and environment, early equipment management and office TPM each get their own records, owners, target dates and dashboard, and 5S audits sit beneath them on the same equipment list.

Operators raise tags on a phone, and tags convert to work orders; PM checklists are filled in the work order. Planned maintenance and calibration run on schedules, and OEE and losses roll up from equipment to line and plant. One point lessons, training and certification are tracked, incidents, near misses and permits to work are managed, and IoT signals can raise work orders automatically.

That puts leadership, training and 5S to work: managers see every pillar's status on its dashboard, training records sit with the people and equipment they concern, and 5S findings become actions with an owner and a date. You can start with routines and records on day one and connect IoT, MES, SCADA, PLC or DCS signals when you are ready (TPM digital transformation).

What do MaintWiz AI agents do for TPM?

MaintWiz AI agents run on your plant's own records (tags, work orders and losses) and generate a list of what needs to be watched. The agent proposes and your people approve, so every action keeps a named owner.

Which MaintWiz module runs each of the eight pillars?

5S sits underneath: see 5S in TPM and 5S audit software.

OEE capture

How is OEE captured?

OEE is reported at equipment, line and plant level with loss stratification, trends and a lost-hours Pareto. Because what OEE software is comes down to stops, counts and planned time held per equipment, the same records serve OEE and the pillar teams. See OEE software and what is OEE. For OEE as a measure and TPM as a system, see the difference between OEE and TPM.

Audits, training records and the other pillars

5S audits are scored by zone with radar and top and low-score views; training plans and sessions are recorded with attendance; quality, safety and early-equipment records have their own screens. The TPM Central area holds goals, best practices and a repository for the programme.

Dashboards

What a TPM dashboard shows

What is a TPM system or TPM management system?

A TPM management system is the combination of routines, roles, records and review cadence that keeps TPM running, whether on paper or in software. The software part holds the records (tags, checklists, losses, audits, training) and the views (dashboards, reports). The management part is the steering group, pillar owners, master plan and review cycle.

Why plants move TPM from paper to a system

Paper and spreadsheets work at the start. They struggle when volumes grow: tags go missing, nobody sees what is overdue, audit scores sit in files, and OEE figures from different lines cannot be rolled up the same way. A shared system gives each item an owner and a date, shows what is open across the plant, and keeps history for the review.

• Abnormality tags get owners, dates and closure tracking.
• Step status per asset shows how far autonomous maintenance has progressed.
• Planned maintenance compliance and backlog are reported from the same records.
• OEE rolls up from equipment to line and plant on one definition.
• Audit scores and training records sit with the equipment and the people they concern.

The same records sit in the Jishu Hozen tags, 5S audits, OEE software, near miss and BBSO, Kaizen and training modules.

Roll-out time

How long does a TPM roll-out with software take?

With MaintWiz the entire TPM can be rolled out in 6 to 8 weeks. Data loads through easy Excel uploads, and the MaintWiz implementation team gives guided project management: a project plan and milestones, module set-up and training (Figure 9).

A 6 to 8 week roll-out, week by week

Guided by the MaintWiz implementation team; data loads through easy Excel uploads

Week 1Week 2Week 3Week 4Week 5Week 6Week 7Week 8

Set-upConfigureTrain and go liveExtend and review

• Kick-off and project plan

• Excel upload: equipment list, master data

• Modules set up with the MaintWiz team

• Tag rules, reason codes and checklists agreed

• Operator training on mobile capture

• Live running in the pilot areas

• Extension across areas and pillars

• Dashboard review by pillar

• SAP, IoT or MES connection, where needed

• Week 2: Data loaded
• Week 4: Routines ready
• Week 6: Operators trained and live
• Week 8: Roll-out complete

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Roles and who reads which view

Roles and entitlements are set up with the customer, so the menus match how the plant works.

Common questions that decide where to start

• Do we have a written loss and OEE definition? If not, write it first.
• Which area has the most visible losses and a willing owner? Start there.
• Do operators have time in the shift for basic care? If not, negotiate it before launch.
• Who will own each pillar? Each owner gets the pillar's dashboard in MaintWiz.
• Is the asset register reliable enough to hold tags and work orders? Fix the worst gaps first.

Bring the answers to the demo: the MaintWiz implementation team turns them into the roll-out plan and loads the owners, loss codes and asset register by Excel upload.

Deployment

Deployment, mobile access, integrations and pricing

MaintWiz is delivered as public software as a service; on-premises deployment is available on request. Operators can capture records on mobile devices. MaintWiz integrates with SAP through the PM and MM modules using web services, can connect IoT, MES, SCADA, PLC and DCS sources, and supports enterprise single sign-on, each in use in live enterprise implementations. Records such as tags, observations, one point lessons and notes can be written in Hindi, Tamil or any other script, because MaintWiz supports Unicode; menus and labels are in English. Data can be exported to XLS and PDF.

Data loads from Excel templates, and the MaintWiz implementation team trains operators and owners during the roll-out. Pricing is quoted on request and tailored to the modules and users you need.

FAQ

Frequently asked questions