TPM Solution Package

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TPM Solution Package
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Want to turn your maintenance function from a simple react and repair function to a reliable system that prevents breakdowns? 

Total Productive Maintenance (TPM) is the vehicle to do this!

What is Total Productive Maintenance?
It is a system that breaks up the complexity of equipment therefore allowing operators and maintenance staff to work together to select, correct, and maintain equipment so that breakdowns seldom occur during production.

TPM focuses your energies to eliminate down-time and unexpected losses and get productivity back to world-class standards. This training package will allow you to implement a robust system that focuses on systemizing your maintenance needs. Your employees will develop a customized Total Productive Maintenance system that produces a high Overall Equipment Effectiveness (OEE). This measures the time you need that equipment to meet daily customer demand. TPM uses this effective analytical tool as a baseline to benchmark actual customer demand time, not the maximum scheduled production time. With our TPM Training Package you can achieve an Overall Equipment Effectiveness (OEE) in the mid to upper 90% without major capital expenditures!

This TPM implementation training kit is designed around a 4 day workshop.

Total Productive Maintenance (TPM) enables participants to:

  • Understand and describe the 6 major losses in equipment effectiveness
  • Assess and evaluate performance of machines and equipment: autonomously and proactively
  • Understand and use the Overall Equipment Effectiveness (OEE) tool for each piece of equipment
  • Improve Overall Equipment Effectiveness (OEE) via application of Total Productive Maintenance tools and techniques
  • Change to a system that prevents, predicts, and is proactive in their approach to maintenance
  • Accomplish actual TPM implementation with measurable results

Goals of Total Productive Maintenance

  • No unplanned downtime
  • Zero defects
  • Zero speed losses
  • No safety issues or accidents
  • Extending the machine’s effective lifetime with little cost


Total Productive Maintenance (TPM) 4 Day Hands-On Workshop

Day 1: TPM Training Portion

  • Total Productive Maintenance Introduction: TPM Perspective
  • Lifecycle costing, True costs, Benefits of TPM
  • Autonomous Maintenance, TPM Inspection
  • Visual Aids and management of maintenance
  • 7 Types of Abnormalities, TPM Tags, One-Point Lessons
  • OEE Worksheet, 6 Major Losses, Practical steps to improvement

Day 2: Shop Floor Implementation

  • Begin “shop floor” phase of training
  • Perform analysis and inspection
  • OEE Measurements and documentation
  • Establish counter measures

Day 3

  • Visual controls and visual systems for equipment
  • Establish cleaning and lubrication standards (TPM Inspection Cards)
  • Formalize mechanical, electrical, and other control standards
  • General inspection training and One-Point Lesson development

Day 4

  • Finalized inspection routine; document; responsibilities; etc.
  • 30 Day Action Log
  • OEE - Overall Equipment Effectiveness
  • Conclude shop floor implementation
  • Review TPM fundamentals
  • TPM team presentations and management review

Package Contents:

The Total Productive Maintenance Solution Package contains the following:  
  • TPM Facilitator Guide (1) – A comprehensive step-by-step review of the presentation and workshop that leads the Facilitator effortlessly through the entire event.
  • TPM Preparation Guide (1) – The Preparation Guide, available only with the solution package, contains a systematic approach to preparing and executing a flawless Lean Manufacturing Workshop. Use as a reference manual for time, scheduling, and overall flow of the workshop.
  • TPM Facilitator Digital Media (1) – A high resolution training focal point that links the Facilitator Guide to the Participant Workbooks. This presentation is designed with Flash Technology instead of Power Point in order to obtain the highest clarity and sharpness of images possible. The presentation loads onto all Windows-based computers.
  • TPM Participant Workbook (8) – Designed for the participants, this workbook reinforces ideas presented by the Facilitator and can be retained for future reference. The workbook contains illustrations, key questions, and space for personal note taking; it also contains a self-assessment form to test participants on key principles outlined in the presentation.
  • Abnormality Assessment Form (1) – This essential form is used to provide criteria for benchmarking TPM projects and for getting objective measurements for each element of TPM.
  • TPM Blue Tags (100) – This tag is an effective communication label to ensure your project team and maintenance are working together.
  • TPM Tag Flow Chart (1) – Reference chart used to properly fill out a TPM Tag.
  • TPM Tag Register (1) – Use this form to log all tagged items during the TPM workshop as well as after the workshop as a tool of continuous improvement.
  • OEE Work Sheet (1) – This is a worksheet to help participants understand the dynamics of the Overall Equipment Effectiveness as a tool for increasing machines availability, performance, and quality.
  • TPM Inspection Form (1) – The inspection form is used to provide a plan-view highlight of the processes required at an area of responsibility.
  • TPM Inspection Cards (1) – These TPM Inspection Cards are attached to the machine in accordance with their respective areas on the TPM Inspection Form.
  • Autonomous Maintenance Form (1) – The Autonomous Maintenance Form is the last form to create before implementing a new TPM system. This form is loaded with all the essential information needed to successfully materialize your TPM program.
  • One-Point Lesson (1) – This form is a tool structured to motivate the trainer to establish all important activities that helps to effectively and efficiently communicate TPM training concepts to participants and employees.
  • 30 Day TPM Action Log (1) – This form is used as the actions to be taken over the 30 days after the completion of a TPM workshop. This form tracks identified TPM issues discovered during the workshop that could not be completed during the workshop.
  • 6 Major Types of Equipment Losses Poster (1) – This poster highlights the six types of equipment losses that effects your OEE.
  • 7 Types of Abnormalities Poster (1) – Classifying the types of abnormalities poster is a bright tool used both in the training room and on the shopfloor.
  • 5 Pillars of TPM Development Poster (1) – This poster is derived from classic Total Productive Maintenance principles and covers the commitment necessary for TPM to succeed.
  • 7 Autonomous Maintenance Steps Poster (1) – This poster summarizes the seven steps to maintaining autonomous maintenance.
  • Lean Mindset Poster (1) – The Lean Mindset poster illustrates the foundation of all company improvement, the cumulative power of many small changes.

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TPM Solution Package

TPM Solution Package