Total Productive Maintenance (TPM) – OEE Training

TPM is one of the most crucial steps in the Lean Transformation journey. It creates a production environment based on stability, reliability, and capability. A stable infrastructure is the critical foundation required not only to initiate tightly integrated Lean practices but also to sustain them effectively.

OEE (Overall Equipment Effectiveness) is a core metric of TPM, indicating how effectively equipment is utilized. It accounts for losses due to breakdowns, setup and adjustments, minor stops, reduced speed, defects, and rework.

Module Content:

• Concept and History of Maintenance
• Maintenance and Cost Relationship
• Waste Analysis in Maintenance Processes
• Concept and History of TPM
• Traditional vs. TPM Approach
• Core Elements of TPM
• TPM Implementation Steps
• Roles of Production and Maintenance Departments
• Types of Maintenance:
• Planned Maintenance
• Preventive Maintenance
• Periodic Maintenance
• Breakdown Maintenance
• Predictive Maintenance
• Autonomous Maintenance
• Cultural Alignment and Teamwork
• Continuous Improvement in Maintenance & Visual Management System
• Failure Tracking Metrics and Calculations:
• MTTR – Mean Time To Repair
• MTBF – Mean Time Between Failures
• MTTF – Mean Time To Failure
• Case Studies, Visual Examples & Sample Applications
• One-Point Lessons
• Relationship Between TPM and JIT (Just-In-Time)
• OEE Concept and Calculation Methods
• Continuous Improvement in OEE

Learning Outcomes for Participants:

By the end of the training, participants will be able to:

• Understand the relationship between maintenance and costs
• Identify necessary types of maintenance for the system
• Prepare autonomous maintenance forms
• Identify autonomous maintenance points on a machine
• Create one-point lesson documents and maintenance forms to improve machine condition
• Calculate MTTR, MTBF, and MTTF rates
• Calculate key OEE components such as Availability, Performance, and Quality rates
• Perform OEE calculations by machine, operator, job order, or shift, and set improvement targets
• Utilize the skills of maintenance personnel more effectively
• Improve work order management systems
• Drive toward zero breakdowns and zero defects at workstations
• Establish a Lean Maintenance Management System

Who Should Attend?

Operations/manufacturing managers, engineering managers, maintenance managers, quality managers, senior supervisors, engineers, and technicians — essentially, decision-makers involved in operational processes and equipment reliability.