SSK 604

Total Productive Maintenance (TPM) Implementation

This intensive five-day practical-oriented training program is designed to equip engineers, supervisors, and maintenance professionals with the knowledge and skills required to successfully implement Total Productive Maintenance (TPM) in manufacturing and industrial environments.The course focuses on building a reliability-driven culture by integrating maintenance and production functions, eliminating losses, improving Overall Equipment Effectiveness (OEE), and empowering operators through Autonomous Maintenance. Participants will learn how to plan, deploy, sustain, and audit TPM initiatives using real-world industrial examples and structured implementation frameworks.

Duration: 2 days

Prerequisites: Basic understanding of manufacturing and maintenance operationsExperience in production, maintenance, or engineering roles is recommendedFamiliarity with basic maintenance concepts is an advantage

Course objectives

Understand TPM philosophy, pillars, and implementation roadmap
Identify and eliminate equipment-related losses
Implement Autonomous Maintenance at shop-floor level
Measure and improve Overall Equipment Effectiveness (OEE)
Establish planned maintenance aligned with TPM goals
Develop operator and technician competency frameworks
Create a reliability-focused organizational culture
Sustain TPM through audits, KPIs, and continuous improvement

Course content

Module 1 TPM Fundamentals & Equipment Loss Analysis

Introduction to Total Productive Maintenance
TPM objectives and benefits
TPM pillars overview:
Autonomous Maintenance
Planned Maintenance
Focused Improvement
Quality Maintenance
Training & Education
Safety, Health & Environment
Roles of management, supervisors, operators, and maintenance
The Six Big Losses in equipment performance
Introduction to OEE concept

Module 2 Autonomous Maintenance (AM) Implementation

Concept and objectives of Autonomous Maintenance
Operator ownership and skill development
7 Steps of Autonomous Maintenance:
Initial cleaning
Eliminate sources of contamination
Establish cleaning and lubrication standards
General inspection training
Autonomous inspection
Standardization
Continuous improvement
Visual controls and tagging systems
Standard work and AM checklists

Module 3 OEE Measurement & Focused Improvement

Detailed OEE components:
Availability
Performance
Quality
Data collection methods for OEE
Loss analysis and Pareto prioritization
Focused Improvement (Kaizen) teams
Problem-solving tools:
5 Why analysis
Fishbone diagrams
Linking OEE improvement to business goals

Module 4 Planned Maintenance, Reliability & Skill Development

Planned Maintenance in TPM environment
Transition from reactive to preventive and predictive maintenance
Equipment criticality analysis
Maintenance standardization and job plans
Basic reliability concepts (MTBF, MTTR)
Training and competency development for operators and technicians
Safety and risk control in maintenance activities

Module 5 TPM Deployment, Audits & Sustainability

TPM implementation roadmap and phases
Pilot area selection and rollout strategy
TPM KPIs and performance tracking
TPM audits and maturity assessment
Management review and leadership involvement
Change management and cultural transformation
Sustaining TPM through standardization and continuous improvement
Review of successful TPM case studies