Total Productive Maintenance for Reliable Operations Training Course

Course overview

Unplanned equipment failure, chronic minor stops, slow changeovers and inconsistent operator care reduce throughput long before a major breakdown appears on a maintenance report. Operations and maintenance teams often respond with urgent repairs, spare-part expedites and overtime, while the underlying losses remain unmeasured or poorly owned. This five-day Total Productive Maintenance (TPM) course gives participants a disciplined way to move from reactive intervention to equipment reliability, stable operating conditions and shared responsibility for asset performance.

Participants learn how to structure a TPM programme around the eight pillars, calculate and interpret Overall Equipment Effectiveness (OEE), identify the Six Big Losses, and build practical loss-elimination plans. The course covers autonomous maintenance, planned maintenance, focused improvement, quality maintenance, early equipment management, training systems, safety and office TPM. Participants use failure-mode analysis, Pareto charts, cause-and-effect analysis, 5 Why questioning, maintenance planning metrics and visual controls to prioritise actions that improve availability, performance and quality.

Instructor-led sessions are supported by equipment-loss cases, OEE calculations, autonomous-maintenance design workshops and team-based root-cause analysis. Participants work with realistic production and maintenance data, then translate the method to their own operating environment. Each participant leaves with a TPM implementation charter, an OEE loss tree, a pilot-area assessment and a 90-day action plan that can be presented to plant leadership or used to launch a site-based improvement initiative.

The course is designed for professionals who already work with production assets, maintenance systems or operational improvement. It is particularly valuable where operations and maintenance need clearer joint ownership of equipment condition, planned work and continuous improvement results.

Course objectives

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

• Calculate OEE from availability, performance and quality data and isolate the Six Big Losses
• Conduct a TPM baseline assessment using the eight-pillar maturity framework
• Design autonomous maintenance standards for cleaning, inspection, lubrication and tightening
• Apply Pareto analysis, 5 Why analysis and fishbone diagrams to eliminate chronic equipment losses
• Build a planned maintenance strategy using failure history, maintenance intervals and criticality
• Create visual management controls for equipment conditions, abnormalities and daily accountability
• Develop a focused-improvement A3 charter with quantified targets, owners and countermeasures
• Produce a 90-day TPM pilot implementation plan with governance, metrics and review cadence

Benefits of attending

Target competencies

Who should attend

• Maintenance Managers — who need to reduce reactive work and establish reliable planned-maintenance routines
• Operations Managers — who are accountable for output, asset availability and production loss reduction
• Production Supervisors — who must embed operator equipment care and escalation discipline on each shift
• Reliability Engineers — who analyse recurring failures and prioritise asset-improvement projects
• Continuous Improvement Managers — who lead Lean, Kaizen or OEE improvement programmes across operations
• Maintenance Planners — who convert equipment history and criticality into executable preventive work plans

Requirements and prerequisites

Participants should have practical experience in a manufacturing, processing, utilities, logistics or asset-intensive operating environment. They should understand basic production measures such as output, downtime, defects, cycle time and preventive maintenance, and be able to interpret simple tables or charts. Familiarity with work orders, maintenance schedules or a CMMS is useful, but participants do not need to be expert users of IBM Maximo or any other system. No advanced statistics, engineering degree, Lean certification or prior TPM qualification is required. Participants should bring examples of recurring equipment losses or maintenance challenges from their workplace where possible.

Training methodology

The course combines instructor-led TPM instruction with calculations, facilitated plant-floor scenarios and structured team workshops. Participants analyse production logs to calculate OEE and classify losses, use failure data to build Pareto priorities, and practise 5 Why and fishbone analysis on chronic equipment problems. Teams create cleaning-inspection-lubrication standards, abnormality tags and planned-maintenance controls for a simulated asset area. On the final day, participants develop an individual TPM pilot charter and 90-day implementation plan, receiving instructor feedback on scope, measures, ownership and governance.

Course outline

Day 1: TPM foundations and equipment-loss visibility

• TPM purpose, principles and the eight-pillar model
• Roles of operators, maintainers, supervisors and leadership
• Overall Equipment Effectiveness formula and data requirements
• Availability, performance and quality loss calculations
• The Six Big Losses and loss-tree construction
• OEE data validation and common measurement errors
• TPM maturity assessment and pilot-area selection criteria

Workshop: Participants calculate OEE from a production data set and produce a loss tree and initial TPM maturity assessment for a selected pilot area.

Day 2: Autonomous maintenance and basic equipment conditions

• Autonomous maintenance step-by-step deployment model
• Cleaning as inspection and sources-of-contamination analysis
• Inspection points for wear, looseness, leakage, heat and vibration
• Cleaning, inspection, lubrication and tightening standards
• Abnormality tagging systems and defect escalation routes
• Visual controls, point lessons and operator skill matrices
• Audit criteria for sustaining basic equipment conditions

Workshop: Participants design a cleaning-inspection-lubrication standard, abnormality tag and layered audit sheet for a simulated production asset.

Day 3: Focused improvement and chronic-loss elimination

• Focused improvement teams and Kaizen project selection
• Pareto analysis of downtime, defect and speed-loss data
• Problem definition using A3 thinking and operational evidence
• 5 Why analysis and cause-and-effect fishbone diagrams
• Failure Mode and Effects Analysis for recurring equipment failures
• Countermeasure selection, validation and standardisation
• Benefit tracking for OEE, cost, safety and quality improvements

Workshop: Teams investigate a chronic stoppage case using Pareto, 5 Why and fishbone analysis, then produce an A3 countermeasure charter.

Day 4: Planned maintenance and reliability integration

• Planned maintenance pillar and maintenance-work taxonomy
• Asset criticality ranking and maintenance-priority setting
• Preventive, predictive and condition-based maintenance strategies
• Failure history coding and ISO 14224 data concepts
• Maintenance planning, scheduling and backlog-control metrics
• Spare-parts criticality and maintenance materials controls
• Using CMMS work orders and history to refine maintenance intervals

Workshop: Participants build a criticality-ranked maintenance plan from asset history and create a preventive-maintenance interval review for a sample equipment set.

Day 5: TPM deployment, governance and pilot planning

• Quality maintenance and defect-prevention conditions
• Early equipment management and maintainability-by-design
• Safety, health and environment integration within TPM
• Education and training pillar with competency progression
• Office TPM support for purchasing, planning and information flow
• TPM governance, tiered reviews and KPI dashboards
• Pilot rollout sequencing, change management and scale-up decisions

Workshop: Participants produce and present a 90-day TPM pilot implementation plan containing scope, OEE target, loss priorities, owners, review rhythm and sustainment measures.

Tools & standards covered

IBM Maximo, Microsoft Excel, ISO 55000, ISO 14224

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