Training Course

Overview

Total Productive Maintenance (TPM) is a comprehensive professional training course designed to equip managers, maintenance professionals, production supervisors, engineers, operators, quality specialists, and continuous improvement practitioners with the knowledge and practical capabilities required to establish high-performing, reliable, and efficient production and operational environments. The course introduces TPM as a structured approach to maximizing equipment effectiveness by involving the entire organization in proactive maintenance, defect prevention, equipment care, and continuous improvement. Participants will learn how to move from reactive maintenance practices toward planned, preventive, predictive, and autonomous maintenance systems that improve equipment reliability, productivity, quality, safety, and cost performance.

The program progresses from foundational TPM principles to advanced implementation and sustainability. Participants will explore the eight pillars of TPM, including Autonomous Maintenance, Planned Maintenance, Quality Maintenance, Focused Improvement, Early Equipment Management, Training and Education, Safety, Health and Environment, and TPM in Administration. The course also examines Overall Equipment Effectiveness (OEE), the six major equipment losses, preventive and predictive maintenance, condition monitoring, failure analysis, maintenance planning, spare-parts management, lubrication management, equipment restoration, standardization, and visual management. Relevant Lean, Kaizen, 5S, Six Sigma, Reliability-Centered Maintenance, and Total Quality Management principles are integrated to demonstrate how TPM can operate as part of a broader operational excellence system.

Practical learning is central to the course. Participants will use OEE calculation sheets, loss trees, equipment registers, criticality matrices, maintenance calendars, autonomous-maintenance checklists, inspection standards, failure-analysis tools, Pareto analysis, 5 Whys, fishbone diagrams, FMEA, maintenance KPIs, condition-monitoring plans, spare-parts classification tools, and TPM maturity assessments. Exercises and case studies cover manufacturing plants, processing facilities, warehouses, utilities, fleet operations, healthcare equipment, logistics systems, and service environments. Participants will practice identifying chronic and sporadic losses, calculating equipment effectiveness, designing maintenance strategies, developing operator care standards, and building improvement plans that address the underlying causes of equipment-related performance losses.

The advanced portion of the course focuses on integrating TPM into organizational performance management and long-term reliability strategy. Participants will learn how to establish equipment ownership, optimize maintenance intervals, develop predictive-maintenance programs, use data to anticipate failures, improve maintainability and availability, manage maintenance costs, and build cross-functional reliability teams. Advanced sessions address maintenance maturity, reliability engineering, condition-based maintenance, digital maintenance systems, predictive analytics, computerized maintenance management systems, spare-parts optimization, maintenance budgeting, and management governance. The course concludes with an integrated TPM implementation framework and capstone project in which participants assess an equipment-intensive operation, identify the major losses and reliability gaps, develop a TPM strategy, design appropriate maintenance and operator-care systems, and create a practical 30-, 60-, and 90-day implementation roadmap.

Course Duration

5 Days (40 Hours)

Target Participants

This course is suitable for:

• Maintenance Managers and Supervisors

• Production Managers and Supervisors

• Plant Managers

• Operations Managers

• Maintenance Engineers

• Reliability Engineers

• Manufacturing Engineers

• Industrial Engineers

• Mechanical and Electrical Engineers

• Facilities and Utilities Managers

• Equipment and Asset Managers

• Production Planners

• Maintenance Planners and Schedulers

• Quality Managers and Quality Engineers

• Lean and Six Sigma Practitioners

• Continuous Improvement Managers and Specialists

• Operations Excellence Professionals

• Warehouse and Logistics Managers

• Fleet and Transport Managers

• Safety, Health, and Environment Professionals

• Maintenance Technicians and Skilled Trades Professionals

• Machine Operators and Team Leaders

• Asset Reliability Professionals

• Engineering Managers

• Project Managers involved in equipment installation or improvement

• Procurement and Spare-Parts Professionals

• Consultants and Operational Excellence Advisors

• Department Heads and Functional Managers

• Entrepreneurs and Business Owners

Course Objectives

By the end of the training, participants will be able to:

• Explain the philosophy, objectives, principles, and business benefits of Total Productive Maintenance.

• Understand TPM as an organization-wide equipment and operational excellence strategy.

• Explain the relationship between TPM, Lean Management, Kaizen, 5S, Six Sigma, and reliability management.

• Understand the eight pillars of TPM and their practical application.

• Identify the six major equipment losses and their impact on productivity.

• Calculate and interpret Overall Equipment Effectiveness.

• Understand equipment availability, performance, and quality components of OEE.

• Identify chronic and sporadic equipment losses.

• Conduct equipment loss analysis and prioritize improvement opportunities.

• Develop equipment criticality classifications.

• Apply preventive, predictive, corrective, and condition-based maintenance principles.

• Distinguish maintenance strategies according to equipment risk and failure characteristics.

• Establish effective Autonomous Maintenance programs.

• Develop operator basic-care standards for equipment.

• Apply cleaning, inspection, lubrication, tightening, and adjustment principles.

• Identify abnormal equipment conditions at an early stage.

• Develop visual standards for equipment inspection and care.

• Establish Planned Maintenance systems and maintenance schedules.

• Develop preventive-maintenance calendars and task lists.

• Improve maintenance planning and scheduling.

• Reduce unplanned downtime and emergency maintenance.

• Apply Focused Improvement techniques to chronic equipment losses.

• Use Pareto analysis to prioritize equipment problems.

• Apply 5 Whys and fishbone analysis to equipment failures.

• Conduct root-cause analysis for recurring equipment breakdowns.

• Apply FMEA to equipment reliability and maintenance planning.

• Establish Quality Maintenance systems to prevent equipment-related defects.

• Link equipment conditions with product and process quality.

• Apply early equipment management principles to new equipment projects.

• Incorporate maintainability and reliability into equipment design and procurement.

• Establish Training and Education systems for operators and maintenance teams.

• Develop equipment competency matrices.

• Integrate safety, health, and environmental considerations into TPM programs.

• Apply TPM principles to administrative and support processes.

• Improve spare-parts availability and inventory management.

• Classify spare parts according to criticality and operational risk.

• Develop effective lubrication-management programs.

• Understand condition monitoring and predictive-maintenance technologies.

• Apply vibration, temperature, oil, electrical, acoustic, and visual monitoring concepts appropriately.

• Understand the role of sensors and industrial data in predictive maintenance.

• Evaluate Computerized Maintenance Management System capabilities.

• Develop meaningful maintenance and reliability KPIs.

• Track MTBF, MTTR, availability, planned-maintenance compliance, and maintenance backlog.

• Establish equipment performance dashboards.

• Develop TPM maturity assessments and implementation roadmaps.

• Build cross-functional TPM teams and equipment ownership structures.

• Establish effective operator-maintenance collaboration.

• Reduce maintenance-related waste, downtime, defects, and operating costs.

• Improve equipment life-cycle performance.

• Develop maintenance budgets and cost-justification models.

• Evaluate maintenance outsourcing and internal capability decisions.

• Integrate TPM with reliability-centered maintenance principles.

• Establish continuous improvement cycles for equipment performance.

• Develop sustainable TPM governance and management-review processes.

• Apply digital technologies and predictive analytics to modern TPM programs.

• Develop an integrated TPM Implementation Framework.

• Create a practical 30-, 60-, and 90-day TPM implementation roadmap.

Course Content

Day 1: TPM Foundations, Equipment Losses, and OEE

Module 1: Total Productive Maintenance (TPM)

Topics

1. Introduction to Total Productive Maintenance and Its Business Objectives
2. TPM Philosophy, Principles, History, and Organizational Benefits
3. TPM and Its Relationship With Lean, Kaizen, Six Sigma, 5S, and Reliability Management
4. The Eight Pillars of Total Productive Maintenance
5. Equipment Ownership, Operator Involvement, and Cross-Functional TPM Teams
6. The Six Major Equipment Losses and Their Operational Impact
7. Overall Equipment Effectiveness: Availability, Performance, and Quality
8. OEE Measurement, Loss Trees, Data Collection, and Performance Analysis
9. Practical Exercise: Calculating OEE and Identifying the Largest Equipment Losses
10. Case Study: Diagnosing a Low-OEE Production Line and Developing Initial TPM Priorities

Day 2: Autonomous Maintenance and Focused Improvement

Module 1: Total Productive Maintenance (TPM)

Topics

1. Autonomous Maintenance Principles and Implementation Stages
2. Initial Equipment Cleaning, Inspection, and Restoration
3. Identifying Abnormalities, Sources of Contamination, and Equipment Deterioration
4. Developing Cleaning, Lubrication, Tightening, and Inspection Standards
5. Visual Management and Autonomous Maintenance Checklists
6. Focused Improvement and Kaizen for Equipment Performance
7. Root-Cause Analysis Using Pareto, 5 Whys, and Fishbone Techniques
8. Applying FMEA and Structured Problem-Solving to Equipment Failures
9. Practical Exercise: Developing an Autonomous Maintenance Program for a Critical Machine
10. Case Study: Eliminating Chronic Breakdowns and Repeated Minor Stops Through Focused Improvement

Day 3: Planned Maintenance, Reliability, and Quality Maintenance

Module 1: Total Productive Maintenance (TPM)

Topics

1. Planned Maintenance Strategy and Maintenance Policy Development
2. Preventive, Corrective, Predictive, and Condition-Based Maintenance
3. Maintenance Planning, Scheduling, Backlog Management, and Work Prioritization
4. Maintenance Interval Optimization and Failure-Pattern Analysis
5. Mean Time Between Failures, Mean Time to Repair, Availability, and Reliability Metrics
6. Condition Monitoring and Predictive-Maintenance Techniques
7. Spare-Parts Criticality, Inventory Optimization, and Lubrication Management
8. Quality Maintenance and Preventing Equipment-Induced Defects
9. Practical Exercise: Developing a Planned-Maintenance Strategy and Reliability KPI Dashboard
10. Case Study: Redesigning a Maintenance Program to Reduce Unplanned Downtime and Quality Losses

Day 4: Advanced TPM Pillars, Safety, and Early Equipment Management

Module 1: Total Productive Maintenance (TPM)

Topics

1. Early Equipment Management and Designing for Reliability and Maintainability
2. Equipment Selection, Commissioning, and Start-Up Reliability
3. Training and Education for Operators, Technicians, and Maintenance Leaders
4. Competency Matrices, Skills Development, and Maintenance Knowledge Management
5. Safety, Health, and Environmental Integration Within TPM
6. TPM in Administration and Supporting Processes
7. Integrating TPM With Reliability-Centered Maintenance and Asset Management
8. Digital TPM, CMMS Platforms, Sensors, Data Collection, and Predictive Analytics
9. Practical Exercise: Developing a Cross-Functional TPM Pillar Implementation Plan
10. Case Study: Implementing TPM Across a Multi-Department Plant With Reliability, Safety, and Skills Gaps

Day 5: TPM Performance Management, Sustainability, and Capstone

Module 1: Total Productive Maintenance (TPM)

Topics

1. TPM Performance Management, KPIs, Dashboards, and Management Reviews
2. TPM Maturity Assessment and Continuous Improvement Governance
3. Maintenance Cost Management, Budgeting, and Business-Case Development
4. Equipment Life-Cycle Cost and Total Cost of Ownership
5. Sustaining Autonomous Maintenance and Planned Maintenance Standards
6. Auditing TPM Practices and Managing Continuous Improvement
7. Building an Enterprise-Wide TPM Culture and Reliability Strategy
8. Developing a Long-Term TPM Transformation Roadmap and Implementation Governance
9. Capstone Exercise: Assessing a Complex Equipment System, Calculating OEE, Identifying Major Losses, Designing TPM Interventions, and Presenting the Improvement Strategy
10. Final Assessment, Capstone Presentation, Peer Review, 30-, 60-, and 90-Day TPM Implementation Roadmap, and Course Review