TPM

There was a time when machine breakdowns were accepted as part of the game. Production managers would scramble, mechanics would be called, spares hurriedly sourced, and everyone would breathe a sigh of relief when the line restarted — until the next breakdown. But quietly, a change has begun. Smart manufacturers are moving from reactive firefighting to proactive control.
This is not just about keeping machines running — it's about transforming uptime into a strategic asset.

Falco TPM is built to deliver exactly that.

Why Traditional Maintenance Fails Today?

Most legacy maintenance systems rely on manual logs, whiteboards, or spreadsheet trackers. Even in factories that have moved to ERP-based ticketing, the data often lives in silos, disconnected from what’s happening on the shop floor.

A few common problems persist:

• Reactive instead of preventive: Maintenance kicks in only after equipment fails
• Lack of ownership: Tickets float without clarity on who’s responsible
• Delayed data: By the time an issue is analysed, the line has already lost hours
• Scattered views: Maintenance KPIs, production loss data, and cost impact sit in separate systems

As machines grow smarter and competition sharper, this just doesn’t cut it anymore.

The Rise of TPM — But Why Has It Stalled

Total Productive Maintenance (TPM) has been around for decades. Many companies attempt TPM rollouts — with colourful boards, red/yellow/green tags, and 5S drives. But most of these efforts stall after the initial push.

Why?

Because TPM was never designed as a paper-based system. It thrives when data flows in real-time, responsibilities are visible, and improvements are measurable. Without a digital backbone, TPM becomes a well-intended project — not a performance engine.

Falco TPM + Asset Suite: Digitizing the Heart of Uptime

Falco’s TPM & Asset Suite is built ground-up to translate TPM philosophy into daily action. It connects machines, people, and performance through a unified platform that replaces whiteboards with dashboards — and confusion with clarity.

Here's what it enables:

• Digital Asset Cards: Every machine has a digital profile with service logs, spares data, SOPs, and risk ratings
• Smart Ticketing: Raise, assign, and resolve issues with full traceability
• Visual TPM Boards: Real-time plant dashboards that reflect downtime status, preventive schedules, and response time trends
• MTTR & MTBF Insights: Metrics that drive behaviour — not just record it
• Cost Linkages: Understand how maintenance delays impact output, cost per unit, and delivery timelines

What’s Different About This Approach

Unlike standalone CMMS (Computerized Maintenance Management Systems), the Falco approach blends maintenance, asset tracking, and production impact in one flow. It is not just about who fixed what — it’s about how every fix improves the bottom line.

A few things stand out:

• Planned maintenance schedules auto-adapt based on machine usage and condition
• Ticket escalation rules ensure issues don’t sleep in the system
• Downtime reasons are standardized for analytics, not just documentation
• Visual alerts let shop floor teams act without navigating multiple systems

The Payoff: Strategic Uptime

What changes when uptime becomes visible and planned?

• Fewer surprises
• More predictable production. – High OEE
• Lower emergency maintenance costs
• Higher on-time deliveries
• Smarter capex planning based on asset fatigue, not gut feel
• Suddenly, maintenance is no longer a “cost centre” — it becomes a performance lever

Conclusion: Quiet Change, Deep Impact

No loud transformation. No sweeping overhaul. Just a quiet shift — one ticket, one asset, one dashboard at a time.
This is how smart operations evolve. Not with slogans, but with systems. Not with audits, but with visibility. And not with luck, but with control.
Falco TPM + Asset Suite is for teams that want to stop chasing breakdowns and start shaping performance.