Total Productive Maintenance - TPM

Total Productive Maintenance (TPM) is an initiative for optimizing the effectiveness of equipment. TPM is team-based productive maintenance and requires active participation by everyone from production workers and maintenance personnel to engineering departments and top management. TPM draws from the behavioral sciences as well as the traditional engineering disciplines in creating a manufacturing environment in which preventive maintenance activities are viewed as everyone's responsibility.

Operators no longer just operate and call the maintenance department when a breakdown occurs.  Maintenance personnel are then free to employ their skills on higher level preventive maintenance activities and overhauls. Everyone views goals of zero breakdowns, maximizing productivity, and zero product defects as shared responsibilities.

Course Objectives: 
  • Understand How and Why Equipment Fails
  • Identify Causes and Types of Equipment Failures
  • Measure Overall Equipment Effectiveness (OEE)
  • Build an Effective Maintenance Team
  • Create a Tracking and Checklist Program
  • Utilize Visual Guides
  • How to Communicate TPM through the whole Facility
Target Audience: 
Course Methodology: 

Presentations, role-plays, group discussion, lectures

Course Outlines: 

Introduction to Total Productive Maintenance (TPM)


  • What is TPM
  • Benefit of TPM
  • Case study of TPM


Proactive vs. Reactive Approach to Total Productive Maintenance


  • Operator involvement
  • Maintenance Personnel Involvement
  • Management involvement


The 8 Pillars of Total Productive Maintenance


  • Maintenance Training
  • Safety, Health & Environment
  • Equipment/Process Improvement
  • Autonomous Maintenance
  • Planned Maintenance
  • New Equipment Management
  • Process Quality
  • Predictive Maintenance


Overall Equipment/ Plant Effectiveness and Loss Analysis

  • Measuring Overall Equipment Effectiveness (OEE)
  • How measurement develops proper focus for maintenance
  • Six big losses resulting from inadequate maintenance

Total Productive Maintenance Improvement Strategies

  • Maintenance Training
  • Safety, Health & Environment
  • Equipment/Process Improvement

Autonomous Maintenance

  • What is Autonomous Maintenance?
  • Benefits of Autonomous Maintenance
  • Indentify potential equipment

Planned Maintenance

  • How to plan a maintenance plan in manufacturing?
  • Benefits of planned Maintenance

Developing an Implementation Strategy and Plan

  • Indentify the TPM for the equipments used in the operational processes
  • Focus on the importance of strategies in TPM
  • Information gathering thru PDCA cycle in TPM

Critical Success Factors for TPM implementation

  • Measurement tools for performance of TPM
  • Frequent review of TPM in organisation
  • Overall benefits of TPM in the organisation



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Jimmy Ong Tel: ‭+60 16 216 1383‬ (Call on Whatsapp for free)