Total Productive Maintenance (TPM)
Implement Total Productive Maintenance across the eight pillars. Participants learn TPM losses and OEE, focused improvement, autonomous, planned and quality maintenance, training, early equipment management, office TPM and safety, moving from firefighting to proactive maintenance.
At a glance
- 9 days · In-house
Who it's for
- Production & maintenance managers and engineers
Learning objectives
- Understand TPM history, losses and OEE
- Implement the 8 TPM pillars
- Apply operator-owner, maintainer-improver and engineer-innovator roles
- Measure TPM with OEE, MTBF and MTTR
- Move from firefighting to preventive, predictive and proactive maintenance
Detailed content
- History and philosophy of TPM
- The loss structure and the six big losses
- OEE calculation and benchmarking
- TPM master plan and organisation
- Loss analysis and prioritisation
- Kobetsu kaizen with why-why analysis
- Measuring improvement results
- The seven steps of jishu hozen
- Initial cleaning and abnormality tags
- Clean-inspect-lubricate standards
- Operator skills and audits
- Maintenance strategies: breakdown, preventive, predictive
- Maintenance planning and scheduling
- MTBF, MTTR and reliability data
- Spare-parts management
- Linking equipment conditions to defects
- Q-component and zero-defect conditions
- Skill matrices and one-point lessons
- Early equipment management and maintenance prevention
- Office TPM for support functions
- Zero-accident goals
- Hazard elimination through TPM
- OEE, MTBF and MTTR dashboards
- Roles: operator, maintainer, engineer
- Shop-floor exercises and on-the-job training
Day-by-day agenda
A typical schedule. In-company versions are tailored to your processes, data and timing.
- TPM foundations
- Focused improvement
- Autonomous maintenance
- Planned maintenance
- Quality maintenance
- Training, early equipment management and office TPM
- Safety, health and environment pillar
- Measuring and sustaining TPM
- Practical workshop applying the tools to participants' cases
- Case study, action plans and course assessment
Practice, tools and assessment
Hands-on practice
- Calculate OEE and the six big losses from a real machine log
- Failure analysis of a recent breakdown (5-Why, fishbone, FMEA)
- Build a preventive / autonomous maintenance plan for one asset
- Aspects-and-impacts register for a real site
Tools and templates you keep
- OEE calculator (Excel)
- PM schedule and CIL (clean–inspect–lubricate) sheet
- Breakdown analysis report template
- Aspects/impacts significance matrix
How learning is assessed
- Pre- and post-course knowledge check
- Assessment of practical exercises by the trainer
- Action plan reviewed at the end of the course
Built on these standards and bodies of knowledge
- JIPM TPM pillars
- SMRP Body of Knowledge
- ISO 55000 (asset management)
How it is delivered
- Public courses in Cairo, in-company programs and live online training
- Practical exercises, case studies and examples from your sector
- Can also run as Train & Stay in Sharm El Sheikh, Hurghada or Cairo
Part of these career paths
- Automotive & Manufacturing Quality · Expert
- Maintenance, Engineering & Reliability · Practitioner
Frequently asked questions
How long is Total Productive Maintenance (TPM)?
The program runs 9 days. In-company versions can be adapted to your needs.
Is the course taught in Arabic or English?
Sessions are usually delivered in Arabic with English technical terms and materials. Full English delivery is available for in-company groups.
Can you run it inside our company?
Yes. In-company programs use exercises built on your own processes. Tell us the group size and preferred timing and we will send a proposal.
Will I receive a certificate?
Participants who complete the program and its assessment receive a certificate from The Excellence Center, which can be verified online.
Is the course taught in Arabic or English?
Sessions are usually delivered in Arabic with English technical terms and materials. Full English delivery is available for in-company groups.
Can you run it inside our company?
Yes. In-company programs use exercises built on your own processes. Tell us the group size and preferred timing and we will send a proposal.
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Get dates, fees and the full outline.
Tell us whether you are joining as an individual or planning a program for your team.