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TPM Total Productive Maintenance
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Total Productive Maintenance (TPM)

Total Productive Maintenance - Impacts on all pillars

Understanding TPM and it's 8 Pillars - 2 hours (Target : Plant Management)
Autonomous Maintenance (AM) Overview - 2 hours (Target : Production Management)
Preventive Maintenance (PM) Overview - 2 hours (Target : Maintenance Management)
Step 1 (including Getting Ready) - 3 full days (Target : Maintenance staff)
Step 2 & 3 - 3 full days (Target : Maintenance staff)
Note : Prerequisite courses - 5S, Kanban systems

What is TPM and how will it help my workplace?

It can be considered as the medical science of machines. Total Productive Maintenance (TPM) is a maintenance program which involves a newly defined concept for maintaining plants and equipment. The goal of the TPM program is to markedly increase production while, at the same time, increasing employee morale and job satisfaction. TPM brings maintenance into focus as a necessary and vitally important part of the business. It is no longer regarded as a non-profit activity. Down time for maintenance is scheduled as a part of the manufacturing day and, in some cases, as an integral part of the manufacturing process. The goal is to hold emergency and unscheduled maintenance to a minimum.

Step 1 (includes Getting Ready)

  • Learn the Tools and Techniques in Planned Maintenance
  • Understand the 7 steps of Planned Maintenance (ref. Japan Institute of Planned Maintenance)
  • Apply Step 1 of Planned Maintenance at your workplace

Step 2 and 3 (includes Workshop)

  • Countermeasures (based on Equipment Failure Map)
  • Why-Why Analysis
  • Zero component/equipment failure due to forced deterioration
  • Identify and determine Cleaning, Inspection and Lubrication(CIL) checkpoints
  • Incorporate functional machine cleaning into Autonomous Maintenance (AM) operating procedures
  • Understand and implement Visual Control Systems (VCS)


Machines and people make money,
Only together can they improve!


Key points/outcomes :

  • Step 1 : Line of sight PM Board, Team formation, Master Plan generation, MTBF, MTBA, MTTR, OEE, A-tagging, Planned Maintenance Schedule, Maintenance Standard, Minor restoration, One Point Lesson(OPL), Kanban systems, Workplace organization (WPO)
  • Step 2 : 5 failure factors, Why-Why Analysis Tool knowledge, Documentation, Team Assessment, Understanding equipment and its components intimately.
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