Total Productive Maintenance (TPM)

Course Duration: 2-3 Days (Adjustable based on participant needs)

Target Audience:

• Maintenance personnel
• Production managers
• Quality control teams
• Operators and supervisors
• Continuous improvement teams

Course Objectives

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

1. Understand the fundamental principles and benefits of TPM.
2. Identify the eight pillars of TPM and their role in productivity improvement.
3. Develop strategies for reducing downtime and improving overall equipment effectiveness (OEE).
4. Implement TPM methodologies to enhance equipment reliability and workplace efficiency.
5. Foster a culture of continuous improvement and proactive maintenance.
6. Establish a structured approach to implementing TPM in their organization.

Learning Outcomes

Upon completion of this course, participants will:

• Gain a comprehensive understanding of TPM principles and their impact on production.
• Learn how to analyze and improve Overall Equipment Effectiveness (OEE).
• Be able to implement autonomous and planned maintenance practices.
• Understand how to integrate TPM with Lean Manufacturing and Six Sigma approaches.
• Develop skills to lead and sustain TPM initiatives in their respective roles.
• Acquire problem-solving techniques for minimizing breakdowns and optimizing equipment performance.

Course Outline

Day 1: Introduction to TPM and its Principles

• Overview of TPM and its significance in manufacturing
• Historical background and evolution of TPM
• Key principles and objectives of TPM
• The Eight Pillars of TPM
• Understanding Overall Equipment Effectiveness (OEE)

Day 2: TPM Implementation Strategies

• Autonomous maintenance: Operator-led maintenance responsibilities
• Planned maintenance: Preventive and predictive approaches
• Focused improvement: Identifying and eliminating chronic losses
• Quality maintenance: Ensuring defect-free production
• Training and development for TPM sustainability
• Safety, health, and environment considerations in TPM

Day 3: Practical Application and Case Studies

• Implementing TPM in real-world scenarios
• Case studies of successful TPM implementation
• Hands-on exercises and group discussions
• Challenges in TPM adoption and overcoming resistance
• Action planning for TPM implementation in participants’ organizations

Training Methodology

This training course employs a combination of:

• Instructor-led Presentations: Concept explanations and best practices
• Interactive Workshops: Group discussions and exercises
• Case Studies: Real-world examples of TPM implementation
• Hands-on Activities: Simulated maintenance exercises
• Assessments & Quizzes: To reinforce learning and evaluate understanding
• Q&A Sessions: Addressing specific concerns and challenges

Assessment & Certification

• Participants will be evaluated through quizzes, group exercises, and a final assessment.
• A certificate of completion will be awarded to participants who successfully complete the course.