LEAN TOTAL PRODUCTIVE MAINTENANCE (TPM)
“Maximizing Equipment Effectiveness and Operator Engagement through Lean TPM Practices”
Course Schedule
| Date | Venue | Fees (Face-to-Face) |
|---|---|---|
| 18 – 20 Aug 2025 | Manama, Bahrain | USD 2495 per delegate |
| 16 – 18 Sep 2025 | Dubai, UAE | USD 2495 per delegate |
Course Introduction
Total Productive Maintenance (TPM) is a foundational pillar of Lean manufacturing, designed to eliminate equipment losses, reduce downtime, and engage operators in sustaining performance. By integrating TPM into daily operations, organizations can achieve significant improvements in productivity, safety, and equipment reliability.
This three-day course provides participants with the tools and methods to implement Lean-based TPM strategies. It covers the eight pillars of TPM, OEE (Overall Equipment Effectiveness), autonomous maintenance, and cross-functional maintenance team development. The training is practical and results-oriented, enabling participants to start applying TPM principles immediately.
Course Objectives
By the end of this course, participants will be able to:
- Understand the philosophy and principles of Total Productive Maintenance (TPM).
- Apply the 8 TPM pillars to improve equipment reliability and performance.
- Calculate and use Overall Equipment Effectiveness (OEE) to drive improvement.
- Implement autonomous maintenance and engage frontline operators.
- Develop preventive and predictive maintenance routines.
- Build cross-functional collaboration between maintenance and production teams.
Key Benefits of Attending
- Gain a proven system for eliminating downtime, breakdowns, and defects.
- Learn to drive cultural change by involving operators in daily maintenance.
- Improve the effectiveness of maintenance resources and equipment uptime.
- Reduce maintenance costs while increasing reliability and output.
- Support Lean transformation with a maintenance strategy aligned to continuous improvement.
Intended Audience
This program is designed for:
- Maintenance supervisors and planners
- Production and plant managers
- Lean practitioners and CI coordinators
- Reliability engineers and technicians
- Operations leaders seeking to embed TPM
Individual Benefits
Key competencies that will be developed include:
- TPM implementation skills
- Equipment loss analysis and OEE improvement
- Autonomous maintenance leadership
- Maintenance planning and task scheduling
- Cross-departmental TPM facilitation
Organization Benefits
Upon completing the training course, participants will demonstrate:
- Increased equipment uptime and asset utilization
- Reduced unplanned breakdowns and stoppages
- Improved operator ownership of equipment
- Enhanced collaboration between operations and maintenance teams
- Structured maintenance processes that support continuous improvement
Instructional Methdology
The course combines Lean theory with TPM tools and real-life applications:
- Concept Briefings – 8 pillars of TPM and their application
- Tools – OEE calculators, maintenance boards, checklists
- Case Studies – TPM success stories from manufacturing and services
- Simulations – OEE analysis and maintenance planning
- Group Exercises – TPM pilot project design and team activity
- Coaching – Continuous improvement strategies and sustainment planning
Course Outline
Training Hours: 7:30 AM – 3:30 PM
Daily Format: 3–4 Modules | Coffee breaks: 09:30 & 11:15 | Lunch Buffet: 01:00 – 02:00
Day 1: Introduction to TPM and Equipment Effectiveness
Module 1: TPM Fundamentals and Lean Alignment (07:30 – 09:30)
- History and purpose of TPM
- TPM vs. traditional maintenance
- Relationship with Lean manufacturing
Module 2: The 8 Pillars of TPM (09:45 – 11:15)
- Overview of the TPM framework
- Focused improvement, autonomous maintenance, planned maintenance
- Quality, training, safety, and early equipment management
Module 3: Measuring Equipment Effectiveness (11:30 – 01:00)
- Understanding downtime, speed loss, and quality loss
- Calculating OEE and interpreting results
- OEE benchmarking and analysis
Module 4: Workshop – OEE Loss Tree Mapping (02:00 – 03:30)
- Participants calculate OEE and identify primary loss categories
Day 2: Implementing TPM Strategies and Tools
Module 5: Autonomous Maintenance (07:30 – 09:30)
- Step-by-step AM implementation
- Cleaning, inspection, and lubrication routines
- Operator roles and visual control tools
Module 6: Planned and Predictive Maintenance (09:45 – 11:15)
- Setting up PM tasks and schedules
- Maintenance logs and failure history
- Predictive tools: vibration, infrared, oil analysis
Module 7: Maintenance Planning and Resource Management (11:30 – 01:00)
- Work order systems and CMMS
- Task standardization and manpower balancing
- Spare parts and inventory control
Module 8: Simulation – TPM Task Planning Exercise (02:00 – 03:30)
- Teams design a TPM plan for a mock equipment case
Day 3: Culture, Teams, and Continuous Improvement
Module 9: Building TPM Teams and Leadership (07:30 – 09:30)
- Operator, technician, and management roles
- Daily meetings and problem-solving routines
- Training and upskilling strategies
Module 10: TPM Audits and Performance Tracking (09:45 – 11:15)
- TPM audit checklists and scoring
- Visual management and TPM boards
- Recognition systems for TPM contribution
Module 11: Embedding TPM into CI Strategy (11:30 – 01:00)
- Linking TPM with 5S, Kaizen, and VSM
- Sustaining momentum and overcoming resistance
- Scaling TPM across multiple lines or facilities
Module 12: Final Workshop – TPM Roadmap Presentation (02:00 – 03:30)
- Teams develop and present a phased TPM implementation plan
Certification
Participants who complete the program will receive a Certificate of Completion in Lean Total Productive Maintenance (TPM), recognizing their ability to lead TPM initiatives and drive equipment and workforce effectiveness.