Lean Business Solutions PLT (LLP0003236-LGN)


Total Productive Maintenance (TPM) is a manufacturing led initiative that emphasizes the importance of people, a "can do" and continuous improvement" philosophy and the importance of production and maintenance staff working together.  This is the only secret recipe available to the world to achieve zero breakdowns of equipment; zero defects produced by the machine and increase the life cycle of the equipment.  TPM is the maintenance system for JIPM.

Thus TPM is concerned with the fundamental rethink of business processes that achieve improvements in cost, quality and speed.  TPM is also crucial in Lean Manufacturing and Six Sigma efforts and eventually to achieve World Class Manufacturing status at OEE 85%.


  • Prevent breakdowns of equipment
  • Eliminate minor stoppages
  • Minimize production defects
  • Reduce maintenance costs
  • Reduce set-up and adjustment losses
  • Maximum line speed
  • Decrease start-up losses.


  • Seminars, group exercise and discussions.
  • Video show / Case study.
  • Practical on the production floor / Gemba.


  • 2 days – 9.00am to 5.00pm
  • Training Fee – SBL Claimable (inclusive of training fees, materials and certificate of attendance).


  • Production, Maintenance and Engineering Personnel who must work together to achieve their goals.
  • Participation from other areas, e.g. Finance and Administration is also recommended because TPM is based on the power of cooperation.


Day 1

  1. Introduction – The Power of TPM
  2. Equipment Condition Analysis
  3. TPM Defined
    • History of TPM
    • Preventive Maintenance and TPM
    • TPM and Product Quality
    • Characteristics and goals of TPM
  4. The Eight Pillars of TPM
  5. Pillar 1 – 5S Housekeeping for TPM
  6. Pillar 2 – Quality Maintenance
    • Sporadic and chronic defects
    • Principles of quality maintenance
  7. Pillar 3 – Six Big Losses
    • Breakdown losses
    • Setup and adjustment losses
    • Idling and minor stoppage losses
    • Reduced speed losses
    • Quality defect and rework
    • Start up / Yield losses
  8. Think Systematically
    • Why Why Analysis
    • PM Analysis


  1. Pillar 4 – Kaizen and Office TPM
    • Kaizen policy
    • Kaizen target
    • Tools used in Kaizen
    • How office TPM supports plant TPM
  2. Where to start TPM?
    • Establish a base line
    • Establish cost of TPM
    • Establish benefits of TPM
    • Case study
  3. How To Measure Equipment Productivity
    • OEE Calculation (Availability x Performance Efficiency x Rate of Quality)
  4. Pillar 5 – Autonomous Maintenance
    • What and Why Autonomous program
    • A 7-step program
  5. Pillar 6 – Training Operators
    • 4 skills to perform Autonomous Maintenance
  6. Pillar 7 – Planned Maintenance
    • Six steps of Planned  Maintenance
  7. Key TPM Strategies for Maintenance Department
    • Corrective Maintenance (CM)
    • Maintenance Prevention (MP)
    • Research and Development
    • Task requiring special stills
    • Overhaul repairs
  8. Pillar 8 – Safety, Health and Environment
  9. 12-step implementation plan.
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