TPM Mastery: From Fundamentals to Real-World Implementation

Name: TPM Mastery: From Fundamentals to Real-World Implementation
Rating: 4.5 (17 reviews)

TPM (Total Productive Maintenance) Mastery: From Foundational Japanese Principles to Real-World Implementation

Created byEric Dao

Last updated 2/2025

English

English [Auto],

What you'll learn

TPM Fundamentals: Understand the origins of TPM, the traditional 8 pillars and 3 key pillars; how to deploy TPM from scratch in a new factory setting.
Autonomous Maintenance (AM) Deep Dive: deploy AM from zero, step-by-step, to foster ownership, enhance technical competency, and drive your facility
Focus Improvement (FI): learn to identify, analyze, and implement countermeasures to eliminate or significantly reduce 16 types of losses, maximizing OEE
Planned Maintenance Mastery: Develop a comprehensive understanding of planned maintenance strategies, including preventive, predictive to gain best MTTR, MTBF
Practical TPM Implementation: Beyond the theory, this course provides practical guidance on deploying TPM in real-world scenarios.

Course content

4 sections • 16 lectures • 4h 41m total length

Definitions - Objectives - Benefits - 8 Pillars - 12 Steps - Structure17:09
learn total productive maintenance, its history and zero targets, including zero breakdowns and zero defects, and explore the eight pillars, twelve steps, and pillars like autonomous maintenance and focused improvement.
TPM Master Plan - Real Model Machine Implementation Part 115:32
This lecture presents a TPM master plan example detailing a phased deployment from top-management announcement to training, pilot machine implementation, and per-machine master plans with KPI reviews and pillar activities.
Real Model Machine Implementation Part 2 - TPM Policy - KPIs - Promotion - Coach24:10
Learn how TPM policy links KPIs to real model machine implementation, with autonomous maintenance, visual standards, and promotion programs driving zero breakdowns, accidents, defects, and loss.

AM Objectives - Connect with Pillars - KPIs - 7 Steps - 4 Phases - Approach - 5S18:24
Explore autonomous maintenance (AM) pillars, seven steps, four phases, and kaizen-driven improvements to reduce stoppages, defects, and accidents through visual controls and operator ownership.
AM Step 0 - Preparation9:00
Form and train a cross-functional AM pillar team, prepare tools and texts, and map machine structure with block diagrams while collecting failure history and checklists.
AM Step 1 - Cleaning with Meaning: Abnormality - SOC - HTA - Audit25:39
Enroll in TPM mastery by learning step one initial cleaning and inspecting to identify seven abnormality types, tag and document findings, analyze root causes, and implement Kaizen countermeasures.
AM Step 2 - Countermeasures - Approach for SOC and HTA11:04
Identify and eliminate sources of contamination in OC and SDA, apply kaizen-driven countermeasures to reduce dust, stains, and foreign materials, and streamline cleaning, lubrication, and inspection for sustained improvement.
AM Step 3 - Standards: CLITA Route Map - Visual Controls - Result - Future Plan25:05
Develop tentative standards for autonomous maintenance step three. Establish cleaning, inspection, and lubrication standards, plus visual control route maps and check sheets to drive kaizen and KPI improvements.

Objectives-16 Types of Loss-KPI-Approach-Master Plan-Organization15:02
Introduce the focused improvement api, or kaizen pillar, and link kpi, master plan, and pillar organization. Apply continuous kaizen to reduce 16 loss types across the factory.
Detail 16 Types of Loss Part 115:36
Explore 16 types of losses in total productive maintenance, including breakdown, setup, startup, minor stoppage, speed, and defect losses, with focus on KPIs like MTBF, MTTR, and downtime.
Detail 16 Types of Loss Part 2-Loss Structure-Cost Tree-Matrix-Equipment Loss23:35
Explore the 16 loss types across manpower, equipment, energy, and material, plus the loss cost tree and loss structure guiding OE and manufacturing costs.

Objectives-Process of Equipment Maintenance-7 PM Steps-Equipment Evaluation15:48
Explore the seven-step process of equipment maintenance within the TPM pillar, including equipment evaluation by safety, quality, delivery, and cost, and selecting maintenance methods for each pack.
Pillar Approach-Connect to Other Pillars-KPI-MTBF-MTTR-Organization15:27
Restore Basic Condition-Improve Weaknesses-AM Support-Sporadic vs Chronic Loss13:18
Apply autonomous maintenance (AM) and PM collaboration with the app to restore basic conditions, implement countermeasures, train operators, and distinguish sporadic versus chronic losses for zero breakdown targets.
Case Study Zero Breakdown Due To Hydraulic Valves of Molding Injection Machine20:01
Case study shows achieving zero breakdowns in a PVC injection molding machine by fixing hydraulic valves through root-cause analysis, countermeasures, and horizontal deployment to other BBC machines.
Time Based Maintenance-Condition Based Maintenance-Maintenance Cost Reduction-16:17
Develop a time based maintenance TBM framework with annual scheduling and inspection-driven corrective actions. Advance to CBM via diagnostics and monitoring while reducing maintenance costs in labor and spare parts.

Requirements

Only need basic concepts of machine maintenance.

Description

Total Productive Maintenance (TPM) Mastery: From Foundational Japanese Principles to Real-World Implementation

This comprehensive Total Productive Maintenance (TPM) course provides a unique blend of foundational knowledge, derived directly from Japanese TPM experts, and extensive practical experience gained over 8 years of implementing TPM at leading international companies across diverse manufacturing sectors, including food & beverage, electronics, and automotive.

This course isn't just theory. It's a distillation of real-world success, compressing years of experience into a practical, actionable framework. We've successfully deployed TPM from the ground up, helping factories achieve world-class status and significantly improve key performance indicators, including MTTR (Mean Time to Repair), MTBF (Mean Time Between Failures), and OEE (Overall Equipment Effectiveness), resulting in substantial cost savings.

While covering all 8 pillars of the TPM house, this training focuses on the critical core:

- Jishu Hozen (Autonomous Maintenance): Empower operators to take ownership of their equipment.

- Kobetsu Kaizen (Focused Improvement): Drive targeted improvements through effective problem-solving.

- Planned Maintenance: Implement a proactive maintenance strategy to minimize downtime.

You'll gain a deep understanding of the theory behind these pillars, reinforced by practical examples and real-world case studies. This course provides the tools and knowledge you need to implement TPM effectively in any manufacturing environment, regardless of industry.

Upon completion, you'll receive a certification of completion, which you can leverage to enhance your career prospects in the field of manufacturing and operations management.

A note on audio: While my native language may influence my spoken English, all video content is subtitled to ensure clear comprehension. The focus remains on delivering high-quality, impactful training content.

Who this course is for:

Maintenance technician, engineer, manager
Manufacturing excellent engineer, supervisor, manager
Process engineer, supervisor, manager
Who want to improve machine efficiency and maintenance performance: OEE, MTTR, MTBF
Who wants to find a methodology for their factory operations to become more profitable in all aspects because TPM is for all aspects of the factory, not just maintenance.

TPM Mastery: From Fundamentals to Real-World Implementation

What you'll learn

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Course content

TPM Overall3 lectures • 57min

Jishu Hozen - Autonomous Maintenance5 lectures • 1hr 29min

Kobetsu Kaizen - Focused Improvement3 lectures • 54min

Planned Maintenance5 lectures • 1hr 21min

Requirements

Description

Who this course is for: