Total Productive Maintenance (TPM): OEE, 8 pillars, reliability.
Claim 5 CPD Points
| Date | Venue | Duration | |
|---|---|---|---|
| 24 - 26 August 2026 | Sandton | 3 Days | |
| 09 - 13 November 2026 | Sandton | 5 Days |
Total Productive Maintenance is a world-class approach to equipment management that involves everyone, working to increase equipment effectiveness. The TPM approach allows you to deploy a comprehensive set of tools and techniques to eliminate all losses across a whole organisation and throughout the value stream.
TPM involves the capabilities of the whole workforce to ensure effective and sustainable improvements are implemented. Improvements to the organisation are made by improving the two core elements of people and equipment. TPM brings maintenance into focus as a necessary and vitally important part of the business. It is no longer regarded as a non-profit activity.
Down time for maintenance is scheduled as a part of the manufacturing day and, in some cases, as an integral part of the manufacturing process. The goal is to hold emergency and unscheduled maintenance to a minimum. Implementing TPM establishes processes and metrics that focus attention on minimizing the non–value-added tasks. The resulting increase in productivity applies not only to the equipment, but to the people working in the manufacturing system as well.
By the end of the Total Productive Maintenance Training, participants will be able to:
An understanding of different types of Maintenance
An understanding of the techniques to eliminate wastes.
An understanding of the 8 Pillars of TPM and their impact on equipment reliability
An understanding of the techniques and methods that promote the company-wide support for a successful TPM implementation.
Awareness of the value of the TPM implementation process.
How to stabilize work station conditions and significantly reduce equipment and system failures.
How to simplify routine maintenance and inspection procedures.
Improve effectiveness of preventive maintenance and promote equipment restoration and reliability.
How TPM leaders can improve operators’ skills in conducting a variety of improvement activities to achieve equipment reliability.
Development of TPM Leaders to promote and co-ordinate improvements.
Understand how to Implement TPM by following our Step-by-Step Roadmap
Recognising and solving the root causes of your equipment failures.
Knowing when to use reliability engineering to get the most benefit for your operation.
Realising where reliability engineering can deliver simple and low-cost reliability improvements to you.
Prospen Africa’s Total Productive Maintenance involves everyone in the organization from operators to senior management in equipment improvement. It encompasses all departments, and the following departments should attend training:
Maintenance artisans and managers
Operations managers and supervisors
Planner & Schedulers
Design Engineering
Project Engineering
Construction Engineering
Purchasing/Procurement
Plant and Site Management
Production Supervisors
Machine Operators with experience and earmarked to be developed to supervisor
Our diverse instructional approaches ensure effective learning:
– Lectures & Presentations: Engage with expert-driven, stimulating content.
– Course Material: Access well-crafted supporting resources.
– Group Work: Collaborate on discussions and case studies for practical insights.
– Workshops & Role-Play: Participate in immersive, scenario-based activities.
– Practical Application: Focus on applying theoretical knowledge in real situations.
– Post-Training Support: Receive extensive support after training for skill implementation.
Module 1: Maintenance in perspective
Introduction to Maintenance
The Objective of Maintenance
Overview of the Types of Maintenance
Breakdown maintenance
Preventive maintenance
Autonomous Maintenance
Reliability Centered Maintenance
Planned Maintenance
Equipment design and predictive maintenance
Equipment Effectiveness and Availability
Overall Equipment Effectiveness (OEE)
Performance/output Efficiency
Group Discusions:
The 12 critical resources required in maintenance
The 12 criterions for teamwork
Module 2: Fundamental Requirements of Effective Maintenance
Discussion of the basic tasks that will result in reliable plant systems, including:
Human Senses
Using Sensor Technology
Careful Inspections
Establishing Thresholds points
Machine Lubrication
Calibration to keep measurement and control instruments within limits
Lock Out Tag Out Procedures (LOTO)
Statistical Process Control basics
Scope of Responsibility: Primary and Secondary Maintenance roles
Module 3: Introduction to Total Productive Maintenance
The Definition of Total Productive Maintenance
The Impact of Total Productive Maintenance
The History of TPM
How TPM compliments the Lean Philosophy
Similarities and differences between TQM and TPM
Module 4: Objectives and benefits of TPM
Objectives of TPM
Eliminating Process Losses
Benefits of TPM
Reduced Variation
Increased Productivity
Reduced Maintenance Costs
Reduced Inventory
Improved Safety
Improved Morale
Module 5: The 8 Pillars of TPM
5S: A foundation for well-running equipment
Pillar 1: Achieve autonomous maintenance (Jishu Hozen)
Pillar 2: Focussed Improvement (Kobetsu Kaizen)
Pillar 3: Planned Maintenance
Pillar 4: Training and Education
Pillar 5: Early Management
Pillar 6: Quality Maintenance
Pillar 7: Office TPM
Pillar 8: Safety, Health and Environment
Module 6: Measuring TPM Effectiveness
TPM Metrics
Overall Equipment Effectiveness (OEE) and the 6 big losses
TPM Activities
TPM Problem Solving by using the 7 quality control tools
Module 7: Implementing an effective Lubrication Program
Overview of Plant Lubrication
Lubrication: Duties and Responsibilities of Management and Employees
The activities to achieve and carry out an effective lubrication program
Establishment of Lubrication Schedules and Improvements in selection and application of Lubricants
Module 8: TPM Implementation Guidelines
Step 1: Announcement of TPM
Step 2: Launch a formal education program
Step 3: Create an organizational support structure
Step 4: Establish basic TPM policies & quantifiable goals
Step 5: Outline a detailed master deployment plan
Step 6: TPM kick-off
Step 7: Improve the effectiveness of each piece of equipment
Step 8 : Develop an autonomous maintenance program for operators
Step 9: Develop a planned or preventive maintenance program
Step 10: Conduct training to improve operation and maintenance skills
Step 11: Develop an early equipment management program
Step 12: Continuous improvement
Module 9: TPM Success Factors and Enablers
Management Support
Focused Approach
Operator Ownership
Just-In-Time Training
Integrated Processes and Schedules
Overcoming the barriers to effective TPM Implementation
Final Recommendations for Improvement
Practical Case Study: Complete an Activity of sample Case study of TPM Implementation
All forms will be provided in printed format, or in Excel / Word format for practical exercises.
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