TPM was invented by JIPM to increase the overall productivity of the process or machine by enhancing maintenance, reducing unscheduled downtime, increasing production capacity, and quality (example the OEE module).
RCM is a boost performance process that focuses on Improving the reliability and life time of the product or machine. This can be done through improving the maintenance, the manufacturing process, and the design process by applying a total quality management system.
TPM views itself as supporting Production by being productive in its tasks i.e. Total Productive Maintenance.
Whereas RCM is centered on Reliability and supporting the entire business with the understanding that Asset Reliability supports all other functions, such as Production Trough-put, Quality, Safety, Environmental Compliance, Asset Management, Sales, Investor Confidence and continued Business Growth.
TPM promotes the use of planned maintenance, e.g. Preventive maintenance and autonomous maintenance.
RCM promotes the use of predictive maintenance (condition monitoring and inspection).
TPM involves the use of autonomous maintenance to reduce the maintenance resources usages and costs. TPM includes eight pillars including safety, education, quality, PM, autonomous maintenance, support systems, focused improvement, and initial phase management.
RCM involves using a special analysis process to determine the best maintenance approach to use based on the cost analysis. Then some tools can be used to minimize the risk of failures for high safety, production, cost components such as FMEA and RCFA. FMEA is a part of the total quality management component and can be effectively used to move any product closer to 100% customer satisfaction.
TPM in maintenance, basically focus on restoring the equipment to its basic condition. TPM strategy is very close to lean and it works best in all common industrial environments where the main goal is zero breakdowns.
RCM identifies the failure modes and quantify the failures as a cost. Minimize the risk of failure and likelihood of failure for critical/safety hazard components and optimize the maintenance performance. It is perfect for catastrophic industries where failures are not accepted e.g. nuclear, aerospace, aircraft...etc.