Total Productive Maintenance for Quality and Productivity Training Course

Course overview

Unplanned stoppages, minor stops, speed loss, defects and extended changeovers erode capacity long before a plant reaches its stated production limit. Total Productive Maintenance (TPM) gives operations and maintenance teams a structured way to expose these losses, restore equipment conditions and prevent recurrence. This course addresses the practical challenge of improving overall equipment effectiveness (OEE) without treating maintenance as a maintenance-department issue alone. Participants learn how operators, technicians, supervisors and engineers can share responsibility for reliable, quality-capable equipment.

The course covers the TPM pillars most directly linked to quality and productivity: focused improvement, autonomous maintenance, planned maintenance, quality maintenance, early equipment management and skills development. Participants calculate and interpret OEE, distinguish availability, performance and quality losses, build loss trees, conduct equipment condition assessments and use Pareto analysis, 5 Whys, fishbone diagrams and failure mode and effects analysis (FMEA). They also learn to create operator care standards, visual controls, lubrication and inspection routines, and maintenance plans based on failure patterns and criticality.

Instructor-led sessions use realistic manufacturing and process-operations cases, equipment-loss data sets, downtime records and defect scenarios. Teams work through a TPM deployment simulation, identify the dominant loss mechanisms on a production line and convert findings into practical countermeasures. Each participant leaves with a TPM improvement charter containing an OEE baseline, loss analysis, target condition, autonomous-maintenance activities, planned-maintenance actions, ownership assignments and a 90-day implementation plan that can be adapted to their workplace.

This intermediate course is suited to professionals responsible for production performance, equipment reliability, process quality or continuous improvement. It is particularly valuable where repeated breakdowns, unstable process conditions, recurring defects or weak operator-maintainer coordination are limiting throughput and delivery performance.

Course objectives

By the end of this course, participants will be able to:

• Calculate OEE and separate availability, performance and quality losses from production data
• Construct a six-big-loss tree to prioritise equipment-related productivity constraints
• Conduct autonomous-maintenance condition checks using cleaning, inspection, lubrication and tightening standards
• Apply Pareto analysis, 5 Whys and fishbone diagrams to recurring downtime and defect problems
• Develop a risk-based planned-maintenance schedule using equipment criticality and failure-history data
• Create quality-maintenance control points that link equipment conditions to defect prevention
• Build a TPM improvement charter with targets, responsibilities, countermeasures and review measures
• Design a 90-day TPM deployment plan for a selected production asset or line

Benefits of attending

Target competencies

Who should attend

• Production Managers — who must improve output, delivery reliability and line performance without compromising quality
• Maintenance Managers — who need to shift work from reactive repair toward planned and condition-based maintenance
• Reliability Engineers — who analyse failure patterns and require a structured TPM deployment method
• Continuous Improvement Managers — who lead OEE, waste-reduction and focused-improvement initiatives
• Quality Managers — who need to connect equipment conditions, process controls and defect prevention
• Operations Supervisors — who coordinate operators and technicians around daily equipment care and escalation

Requirements and prerequisites

Participants should have basic experience of production, maintenance, quality or continuous-improvement work in an operational setting. They should be comfortable reading simple production reports, downtime logs, defect data and work instructions, and should understand basic terms such as preventive maintenance, cycle time, downtime and root cause. Familiarity with Excel is useful for OEE calculations and loss analysis. Prior TPM certification, advanced statistics, PLC programming, vibration analysis or CMMS configuration is not required. Participants from non-manufacturing asset-intensive operations can attend if they bring an equipment or service-process example to use during exercises.

Training methodology

The course combines instructor-led TPM instruction with analysis of production-line loss data, equipment-condition examples and defect records. Participants calculate OEE in Excel, build loss trees, assess a simulated asset against basic-condition standards and practise root-cause analysis on recurring stoppage and quality cases. Small groups develop operator inspection points, planned-maintenance actions and visual management controls for a case-study line. On the final day, each participant converts the methods into a workplace TPM charter and 90-day implementation plan, reviewed against operational feasibility by the instructor and peers.

Course outline

Day 1: TPM foundations and OEE loss visibility

• TPM principles, pillars and the shared ownership model
• Relationship between equipment condition, quality and throughput
• OEE calculation for availability, performance and quality
• The six big losses and their operational signatures
• Planned production time and loss-data integrity
• Loss trees, Pareto charts and production-loss prioritisation
• TPM maturity assessment and deployment starting points

Workshop: Participants analyse a production data set, calculate OEE, build a loss tree and identify the highest-priority loss for intervention.

Day 2: Autonomous maintenance and basic equipment conditions

• Autonomous maintenance steps and operator-maintainer boundaries
• Initial cleaning as inspection and abnormality detection
• Sources of contamination and hard-to-access inspection points
• Cleaning, inspection, lubrication and tightening standards
• Tagging systems for abnormalities and defect escalation
• Visual controls, centre lines and one-point lessons
• Daily management boards and operator ownership measures

Workshop: Teams create a basic-condition restoration plan and a draft cleaning, inspection, lubrication and tightening standard for a case-study machine.

Day 3: Planned maintenance and equipment reliability

• Reactive, preventive, predictive and condition-based maintenance strategies
• Asset criticality ranking and maintenance-priority decisions
• Failure modes, functional failures and failure consequences
• FMEA for maintenance planning and risk reduction
• Maintenance task selection and interval optimisation
• Work-order history analysis and recurring-failure coding
• Spare-parts criticality and maintenance planning interfaces

Workshop: Participants complete an equipment criticality review and FMEA, then produce a risk-based planned-maintenance task list.

Day 4: Quality maintenance and focused improvement

• Quality-maintenance conditions and defect-prevention logic
• Linking machine parameters, wear conditions and quality characteristics
• Defect stratification by machine, shift, product and failure mode
• Focused improvement using the PDCA cycle
• 5 Whys, fishbone diagrams and cause-and-effect verification
• Kaizen countermeasures for minor stops and speed losses
• Control plans, reaction plans and countermeasure follow-up

Workshop: Groups investigate a recurring defect and minor-stop case, verify likely causes and prepare a focused-improvement countermeasure plan.

Day 5: TPM deployment, governance and sustainment

• TPM deployment sequencing and pilot-area selection
• Target setting for OEE, breakdowns, defects and planned-maintenance compliance
• Roles of operators, technicians, supervisors and TPM steering teams
• Tiered performance reviews and escalation routines
• TPM scorecards, leading indicators and audit measures
• Early equipment management and maintainability feedback
• Ninety-day implementation planning and benefits tracking

Workshop: Each participant develops and presents a TPM improvement charter and 90-day action plan for an asset, line or operational area.

Tools & standards covered

Microsoft Excel, SAP Plant Maintenance (SAP PM), ISO 55000 Asset Management, ISO 14224 Petroleum, petrochemical and natural gas industries — collection and exchange of reliability and maintenance data

A typical training day

Live online deliveries follow the same structure in the East Africa Time zone, with shorter screen blocks and longer breaks.

What the fee includes

How you can take this course

Certification

Participants who complete the full five days receive the Skillset Development Certificate of Completion, stating the course title, course code, dates and delivery format — suitable for professional-development records and employer reimbursement.

Frequently asked questions