Total Productive Maintenance (TPM) Implementation

Maintenance and Engineering October 25, 2025
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Introduction

Total Productive Maintenance (TPM) is a comprehensive strategy for maximizing the effectiveness of equipment throughout its entire life by involving all departments, especially production, in maintenance activities. This course provides a complete roadmap for implementing the eight pillars of TPM, focusing heavily on **Autonomous Maintenance (AM)** and **Planned Maintenance (PM)**. Participants will learn how to calculate Overall Equipment Effectiveness (OEE), establish a strong foundation of basic equipment conditions, and foster a culture of cross-functional collaboration where operators take ownership of their assets, leading to reduced losses and improved productivity.

Objectives

Upon completion of this course, participants will be able to:

  • Explain the philosophy and benefits of Total Productive Maintenance (TPM).
  • Calculate and analyze Overall Equipment Effectiveness (OEE) and its components.
  • Implement the seven steps of Autonomous Maintenance (AM) and operator involvement.
  • Structure the Planned Maintenance (PM) pillar for systematic, proactive care.
  • Identify and quantify the "Six Big Losses" that reduce equipment effectiveness.
  • Establish the foundation for equipment reliability (cleaning, lubrication, tightening).
  • Develop a TPM implementation master plan and pilot program.
  • Integrate TPM principles with existing Lean and Continuous Improvement initiatives.

Target Audience

  • Production and Operations Managers
  • Maintenance Managers and Supervisors
  • Continuous Improvement and Lean Facilitators
  • Plant and Manufacturing Engineers
  • Lead Operators and Autonomous Maintenance Team Leaders
  • Quality Assurance Personnel

Methodology

  • Hands-on workshop on calculating OEE and identifying the Six Big Losses
  • Group activity simulating the seven steps of Autonomous Maintenance implementation
  • Case studies demonstrating successful TPM implementation across different industries
  • Discussions on overcoming resistance to change and fostering collaboration
  • Individual assignment on mapping a TPM pillar to specific KPIs and objectives

Personal Impact

  • Develop world-class process and system implementation skills.
  • Master the calculation and analysis of OEE, a key business metric.
  • Gain expertise in cross-functional team leadership and collaboration.
  • Improve problem-solving skills through hands-on OEE loss analysis.
  • Become a recognized change agent and improvement facilitator.

Organizational Impact

  • Maximize Overall Equipment Effectiveness (OEE) and production output.
  • Significantly reduce equipment breakdowns and minor stoppages.
  • Foster a culture of shared ownership between maintenance and operations.
  • Extend asset life and reduce the total cost of ownership.
  • Increase job satisfaction and morale through empowered employee involvement.
  • Achieve measurable reductions in quality defects and production losses.

Course Outline

Unit 1: TPM Fundamentals and OEE

Introduction to TPM
  • Defining the goals and the eight pillars of Total Productive Maintenance.
  • The importance of cross-functional involvement (Maintenance, Production, Engineering).
  • Establishing a foundation of basic equipment conditions (5S and Visual Management).
Measuring Equipment Effectiveness (OEE)
  • Defining the three components of OEE (Availability, Performance, Quality).
  • Identifying and quantifying the "Six Big Losses" that drive OEE down.
  • Techniques for accurate OEE data collection and analysis.

Unit 2: The Autonomous Maintenance (Jishu Hozen) Pillar

Autonomous Maintenance (AM) Steps
  • The seven steps of AM: Initial cleaning, addressing contamination, establishing standards.
  • Developing effective operator training and certification programs.
  • Integrating AM checks into standard operating procedures.
Operator Ownership and Empowerment
  • Shifting mindset from "I operate it" to "I own it."
  • Creating effective visual controls and Poka-Yoke systems.
  • Facilitating operator-led small group activities for continuous improvement.

Unit 3: Planned Maintenance (PM) and Quality Pillars

Planned Maintenance System
  • Structuring the PM pillar to support Autonomous Maintenance.
  • Developing time-based, condition-based, and predictive maintenance schedules.
  • Maximizing PM effectiveness and schedule compliance.
Quality Maintenance (QM)
  • Integrating quality checks into maintenance and operator routines.
  • Identifying and addressing maintenance-related quality defects.
  • Zero-defect strategy implementation.

Unit 4: Other Key Pillars

Early Equipment Management (EEM)
  • Designing new equipment for maintenance-free and easy operation.
  • Life cycle costing and maintainability review during design phase.
  • Vertical start-up strategies and rapid knowledge transfer.
Education and Training (E&T)
  • Assessing skill gaps and developing multi-skilled teams.
  • Designing structured training programs for all personnel (operators, maintenance).
  • The role of mentorship and knowledge transfer in TPM.

Unit 5: TPM Implementation and Sustenance

TPM Implementation Roadmap
  • Developing the TPM master plan and establishing pilot areas.
  • Defining key metrics and setting measurable objectives for each pillar.
  • Techniques for sustaining the TPM effort and recognizing success.
Office TPM and Safety
  • Applying TPM principles to administrative functions (Office TPM).
  • The importance of the Safety, Health, and Environment (SHE) pillar.
  • Creating a zero-accident and zero-pollution environment.

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