Module 1: Introduction to TPM

 

• 1.1 Overview of TPM and its objectives
• 1.2 The evolution of TPM in modern industries
• 1.3 Understanding TPM principles and benefits
• 1.4 Key elements of TPM implementation
• 1.5 TPM’s role in World-Class Manufacturing
• 1.6 TPM benefits
• 1.7 TPM prerequisites

 

Module 2: Understanding Overall Equipment Effectiveness (OEE)

 

• 2.1 Definition and significance of OEE
• 2.2 Components of OEE: Availability, Performance, and Quality
• 2.3 Identifying and eliminating machine losses
• 2.4 Calculating and interpreting OEE results
• 2.5 Strategies for improving OEE
• 2.6 Case studies on OEE implementation
• 2.7 OEE exercise

 

 

Module 3: TPM Pillars and Implementation Strategies

 

 

• 3.1 Autonomous maintenance: Principles and benefits
• 3.2 Planned maintenance: Creating proactive maintenance plans
• 3.3 Focused improvement: Techniques to eliminate chronic losses
• 3.4 Education and training: Building a skilled workforce
• 3.5 Early equipment management: Ensuring reliability in new equipment

Module 4: Developing a TPM Roadmap

 

• 4.1 Assessing current maintenance practices
• 4.2 Setting TPM goals and KPIs
• 4.3 Developing an action plan for TPM implementation
• 4.4 Engaging employees in the TPM journey
• 4.5 Overcoming challenges in TPM adoption

 

Module 5: Equipment Loss Analysis and Countermeasures

 

 

• 5.1 Understanding the Big Six Machine Losses
• 5.2 Identifying root causes of equipment inefficiencies
• 5.3 Implementing countermeasures to reduce losses
• 5.4 Applying predictive maintenance techniques
• 5.5 Measuring improvements in equipment reliability

Module 6: Autonomous Maintenance in Action

 

• 6.1 Steps for implementing autonomous maintenance
• 6.2 Operator involvement in maintenance activities
• 6.3 Visual management and 5S for equipment upkeep
• 6.4 Conducting regular maintenance inspections
• 6.5 Standardizing autonomous maintenance practices

 

 

Module 7: Quality Maintenance and Continuous Improvement

 

 

• 7.1 Integrating TPM with quality management systems
• 7.2 Defect prevention and error-proofing techniques
• 7.3 Quality control vs. quality assurance
• 7.4 Establishing a feedback loop for process improvements
• 7.5 Case studies on successful TPM-driven quality improvement

Module 8: Planned Maintenance and Predictive Techniques

 

• 8.1 Importance of planned maintenance
• 8.2 Developing a preventive maintenance schedule
• 8.3 Predictive maintenance tools and technologies
• 8.4 Implementing condition-based monitoring
• 8.5 Analyzing maintenance data for decision-making

 

Module 9: Implementing TPM in Various Industries

 

 

• 9.1 Adapting TPM strategies for different industry sectors
• 9.2 Case studies on successful TPM implementations
• 9.3 Overcoming industry-specific TPM challenges
• 9.4 Measuring TPM success through key performance indicators

Module 10: Leadership and Culture Change for TPM Success

 

• 10.1 Role of leadership in driving TPM initiatives
• 10.2 Creating a TPM-oriented organizational culture
• 10.3 Employee engagement strategies for TPM sustainability
• 10.4 Continuous monitoring and improvement in TPM practices
• 10.5 Best practices for long-term TPM success

 

Module 11: TPM Performance Measurement and Continuous Development

 

 

• 11.1 Key metrics for evaluating TPM effectiveness
• 11.2 Conducting TPM audits and assessments
• 11.3 Refining TPM strategies based on data insights
• 11.4 Encouraging a culture of continuous improvement
• 11.5 Industry trends and future of TPM
• 11.6 Continuous improvement and development