Total Productive Maintenance (TPM) Course

Lesson 1 • TPM vs. Traditional Maintenance Approaches

Contrasts reactive, preventive, and predictive maintenance with TPM. Clarifies where TPM adds unique value beyond conventional programs.

Lesson 2 • Organizational Roles in TPM

Maps responsibilities across operators, technicians, engineers, and managers. Establishes accountability structures needed before implementation begins.

Lesson 3 • History and Evolution of TPM

Traces TPM from preventive maintenance roots to the JIPM model. Provides context for why TPM emerged as a competitive manufacturing strategy.

Lesson 4 • Core Philosophy and Principles

Defines the zero-loss mindset and employee ownership culture central to TPM. Links philosophy to measurable operational outcomes.

Lesson 1 • Overview of the Eight-Pillar Framework

Presents the eight pillars as a unified architecture supporting equipment excellence. Shows how pillars interact and reinforce one another.

Lesson 2 • Autonomous and Planned Maintenance Pillars

Covers operator-led care and scheduled technician activities as the TPM foundation. Distinguishes daily checks from periodic overhaul planning.

Lesson 3 • Early Equipment Management and Office TPM

Introduces design-stage loss prevention and the extension of TPM principles to administrative functions. Broadens TPM scope beyond the shop floor.

Lesson 4 • Education, Training, and Safety Pillars

Addresses skill-building programs and the creation of accident-free workplaces. Demonstrates how competency and safety underpin all other pillars.

Lesson 1 • Data Collection Methods for OEE

Covers manual logging, sensor-based capture, and SCADA integration for OEE data. Ensures data accuracy and consistency across shifts.

Lesson 2 • The Six Big Losses Framework

Categorizes the six major equipment losses that reduce OEE. Enables precise loss attribution before improvement efforts begin.

Lesson 3 • OEE Components and Formula

Defines availability, performance, and quality rate and shows how they combine into OEE. Establishes the mathematical foundation for all subsequent analysis.

Lesson 4 • Setting OEE Improvement Targets

Guides target-setting using baseline data, benchmarks, and business priorities. Connects OEE goals to production and financial objectives.

Lesson 1 • Lubrication Management by Operators

Covers lubrication types, intervals, and operator-level application methods. Reduces lubrication-related failures through disciplined operator routines.

Lesson 2 • Cleaning as Inspection Technique

Reframes cleaning as a diagnostic activity that reveals hidden defects. Trains operators to detect abnormalities during routine cleaning tasks.

Lesson 3 • One-Point Lessons and Visual Standards

Introduces one-point lessons as concise, visual job aids for autonomous tasks. Standardizes knowledge transfer at the point of use.

Lesson 4 • Seven Steps of Autonomous Maintenance

Walks through each step from initial cleaning to full self-management. Provides a structured roadmap operators follow to build ownership progressively.

Lesson 1 • Equipment Criticality and Risk Assessment

Ranks equipment by failure impact using criticality and risk matrices. Prioritizes maintenance resources toward highest-consequence assets.

Lesson 2 • Maintenance Strategy Selection

Compares time-based, condition-based, and reliability-centered strategies. Matches the right strategy to each equipment class and failure mode.

Lesson 3 • Maintenance Scheduling and Work Orders

Builds master maintenance schedules and standardized work order processes. Ensures tasks are planned, assigned, and completed on time.

Lesson 4 • Maintenance Performance Tracking

Defines KPIs such as MTBF, MTTR, and planned maintenance compliance. Uses trend data to continuously improve the maintenance program.

Lesson 1 • Root Cause Analysis Methods

Applies Why-Why analysis, fishbone diagrams, and PM analysis to find true root causes. Prevents recurrence by addressing causes rather than symptoms.

Lesson 2 • Countermeasure Development and Testing

Guides teams from root cause to verified countermeasure through structured testing. Ensures solutions are robust before full-scale implementation.

Lesson 3 • Standardizing and Sustaining Improvements

Embeds gains into standards, procedures, and training to prevent regression. Closes the improvement cycle with horizontal deployment across similar equipment.

Lesson 4 • Loss Identification and Prioritization

Uses OEE data and loss trees to identify and rank improvement opportunities. Focuses team energy on the highest-impact losses first.

Lesson 1 • Defect Rate Reduction Tracking

Establishes metrics and visual boards to track defect reduction progress. Sustains quality gains through regular review and accountability routines.

Lesson 2 • Quality Maintenance Matrix Construction

Builds the QM matrix linking equipment conditions to quality defects. Provides a visual tool for prioritizing condition-based quality controls.

Lesson 3 • Equipment-Quality Relationship Analysis

Maps how equipment parameters affect product quality characteristics. Establishes the analytical foundation for quality maintenance activities.

Lesson 4 • Statistical Process Control in TPM

Applies control charts to monitor equipment-driven process variation. Triggers maintenance action before quality defects reach the customer.

Lesson 1 • Building a Self-Sustaining TPM Culture

Embeds TPM behaviors into daily routines, recognition systems, and leadership practices. Transitions TPM from a project to a permanent operational discipline.

Lesson 2 • TPM Training and Competency Development

Designs role-specific training curricula and competency assessment frameworks. Ensures every level of the organization can execute its TPM responsibilities.

Lesson 3 • TPM Deployment Roadmap Design

Structures a phased implementation plan from preparation through maturity. Aligns milestones with organizational capacity and business priorities.

Lesson 4 • Leadership Engagement and Change Management

Secures executive sponsorship and manages resistance during TPM rollout. Builds the coalition needed to sustain long-term cultural change.