Total Productive Maintenance Training

The TPM Beginners Training Program is a 2-day course designed to build a strong foundation for teams embarking on their TPM journey. Beginner level TPM training module covers introduction to TPM basics and 2 key pillars of TPM – Focussed Improvement and Autonomous Maintenance Steps 1 & 2. 

Day 1:

• Introduction to TPM

• • Understand need for implementing TPM & benefits
  • TPM Objectives & Overview of TPM pillars

• Focused Improvement

• • Understanding & measuring OEE, OEE 16 Losses, Loss cost tree – converting losses into money value
  • Systematic Root cause analysis approach covering Pareto analysis, Cause & Effect diagram, Why Why Analysis & Countermeasures to reduce major losses

• Autonomous Maintenance Step 1 & 2

• • Steps 1 & 2 of to gain understanding on how to correctly detect & correct abnormalities and take countermeasures to eliminate repeat problems and reduce CLIT time

Day 2 

• Autonomous Maintenance Step 3
  • Learn to create cleaning, lubrication, inspection & tightening standards
• Planned Maintenance Step 1,2,3
  • Learn about PM Step 1, 2 & 3 covering support for Autonomous maintenance, Equipment ranking, Time based Maintenance & Condition based maintenance 
  • Establish effective Spare Parts Inventory Management to minimize delays and downtimes due to Spares non-availability, Optimize Spare parts inventory and Reduce

The TPM Intermediate Training Program is a 3-day course designed to strengthen your team’s knowledge and skills to effectively reduce chronic losses. Intermediate TPM training module additionally covers 3 new pillars of TPM including Education & Training, Quality Maintenance and Safety, Health & Environment 

Day 1:

• Introduction to TPM

• • Understand need for implementing TPM & benefits
  • TPM Objectives & Overview of TPM pillars
• Focused Improvement
  • Understanding & measuring OEE, OEE 16 Losses, Loss cost tree – converting losses into money value
  • Systematic Root cause analysis approach covering Pareto analysis, Cause & Effect diagram, Why Why Analysis & Countermeasures to reduce major losses
• Autonomous Maintenance Step 1 & 2
  • Steps 1 & 2 of to gain understanding on how to correctly detect & correct abnormalities and take countermeasures to eliminate repeat problems and reduce CLIT time

Day 2 

• Autonomous Maintenance Step 3
  • Learn to create cleaning, lubrication, inspection & tightening standards
• Planned Maintenance Step 1,2,3
  • Learn about PM Step 1, 2 & 3 covering support for Autonomous maintenance, Equipment ranking, Time based Maintenance & Condition based maintenance 
  • Establish effective Spare Parts Inventory Management to minimize delays and downtimes due to Spares non-availability, Optimize Spare parts inventory and Reduce

Day 3

• Education & Training 

• • Learn to measure operator skills through skill trainings and key technical skills to implement TPM pillars effectively

• Quality Maintenance

• • Categorise Quality Defect / Reworks as phenomenon, identify countermeasures to be implemented, Create QA matrix and how to use 3M analysis

• Safety, Health & Environment

• • Conduct Risk analysis and Hazard identification to prevent incidents and occupational accidents., Root cause analysis on Near misses and accidents

The TPM Advanced Training Program is a 5-day course designed to deepen your team’s knowledge and skills for effective TPM implementation. This advanced module provides a comprehensive understanding of all TPM pillars, supported by real-world case studies.

Day 1

• Introduction to TPM

• • Understand need for implementing TPM & benefits
  • TPM Objectives & Overview of TPM pillars

• Focused Improvement

• • Understanding & measuring OEE, OEE 16 Losses, Loss cost tree – converting losses into money value
  • Systematic Root cause analysis approach covering Pareto analysis, Cause & Effect diagram, Why Why Analysis & Countermeasures to reduce major losses

• Autonomous Maintenance Step 1 & 2

• • Steps 1 & 2 of to gain understanding on how to correctly detect & correct abnormalities and take countermeasures to eliminate repeat problems and reduce CLIT time

Day 2

• Autonomous Maintenance Step 3
  • Learn to create cleaning, lubrication, inspection & tightening standards

• Planned Maintenance Step 1,2,3
  • Learn about PM Step 1, 2 & 3 covering support for Autonomous maintenance, Equipment ranking, Time based Maintenance & Condition based maintenance
  • Establish effective Spare Parts Inventory Management to minimize delays and downtimes due to Spares non-availability, Optimize Spare parts inventory and Reduce

Day 3

• Autonomous Maintenance Step 4 & 5

• • Creation of Single line diagrams, Check criteria, General inspection sheets and know why sheets, How to train workers on Train workers on General inspection sheet

• Focused Improvement – SMED 
  • Implement SMED to reduce changeover time

• Planned Maintenance – Predictive Maintenance

• • Understand application and benefits of predictive maintenance techniques such as as Thermography analysis, Ultrasound analysis, Vibration analysis etc to proactively identify and address abnormalities

Day 4

• Education & Training 

• • Learn to measure operator skills through skill trainings and key technical skills to implement TPM pillars effectively

• Quality Maintenance 

• • Categorise Quality Defect / Reworks as phenomenon, identify countermeasures to be implemented, Create QA matrix and how to use 3M analysis

• Safety, Health & Environment

• • Conduct Risk analysis and Hazard identification to prevent incidents and occupational accidents., Root cause analysis on Near misses and accidents

Day 5

• Planned Maintenance – FMEA
  • Failure modes and effects analysis to proactively identify possible failure modes, effects and counteremeasures to be implemented

• Early Equipment Management
  • Establish system to review design to reduce losses due to design flaws / faults or improve design to reduce 16 losses, and for Maintenance prevention

• TPM in Office
  • Process mapping to identify major gaps and losses in all support functions (finance, HR, supply chain, procurement etc)