The packs follow the twelve TPM implementation steps, so you can train only for the step your plant is on.
Which pack to choose
| Where your plant is | The pack that fits |
|---|---|
| Have not started TPM at all | Pack 1 — Starting TPM |
| Policy declared, but no idea where the loss is | Pack 2 — Focused Improvement and OEE |
| Operators still do not care for their own machines | Pack 3 — Autonomous Maintenance |
| Maintenance is still mostly reactive | Pack 4 — Planned Maintenance |
| You want the internal team to train each other | Pack 5 — Education & Training |
| Defects keep recurring, or new equipment is coming | Pack 6 — Initial Phase & Quality Maintenance |
| The office keeps production waiting | Pack 7 — Office Improvement |
| Running a while; time to reinforce and measure | Pack 8 — Safety and Total Application |
Pack 1 — Starting TPM
Steps 1–6: declaration, introduction, organisation, targets, master plan, kick-off
Courses: 4 Total: 5 days
| Course | Days | Audience |
|---|---|---|
| TPM for Manager | 0.5 day | All managers |
| Introduction to TPM | 0.5 day | All employees |
| TPM: Getting Started (project team workshop) | 2 day | TPM project team |
| How to Work as TPM Promoter | 2 day | TPM promoter |
Pack 2 — Focused Improvement and OEE
Step 7: production efficiency improvement — OEE and focused improvement
Courses: 6 Total: 10 days
| Course | Days | Audience |
|---|---|---|
| How to Implement TPM: role, responsibility and linkage of eight pillars | 2 day | FI, AM, PM and ET pillar leads |
| Focused Improvement | 2 day | FI pillar |
| Loss tree and OEE workshop | 1 day | FI pillar |
| Machine improvement (Kaizen workshop) | 1 day | Improvement teams |
| Root cause analysis: Why-Why and P-M analysis | 2 day | Engineers and improvement teams |
| Poka-Yoke and visual control | 2 day | Improvement teams |
Pack 3 — Autonomous Maintenance
Step 7.2: autonomous maintenance
Courses: 5 Total: 9 days
| Course | Days | Audience |
|---|---|---|
| Autonomous Maintenance | 2 day | AM pillar and all production |
| How to use 7 QC tools in TPM implementation | 2 day | Production |
| Root cause analysis: Why-Why and P-M analysis | 2 day | Production and engineering |
| Poka-Yoke and visual control | 2 day | Production |
| How to audit AM effectively | 1 day | AM audit team |
Pack 4 — Planned Maintenance
Step 7.3: planned maintenance
Courses: 9 Total: 12 days
| Course | Days | Audience |
|---|---|---|
| Planned Maintenance | 1 day | PM pillar |
| Machine reliability improvement (MTTR workshop) | 1 day | Maintenance |
| PM optimisation (MTBF workshop) | 1 day | Maintenance |
| CBM and predictive maintenance | 2 day | Maintenance |
| Maintenance budget planning and control | 1 day | Maintenance managers |
| Maintenance cost analysis for cost reduction | 1 day | Maintenance managers |
| Root cause analysis: Why-Why and P-M analysis | 2 day | Maintenance |
| FMEA | 2 day | Engineering |
| Maintenance spare part inventory and stock control | 1 day | Maintenance and stores |
Pack 5 — Education & Training
Step 7.4: training and skill development
Courses: 4 Total: 6 days
| Course | Days | Audience |
|---|---|---|
| Training and skill development | 1 day | ET pillar |
| TPM train-the-trainer | 3 day | Internal trainers |
| Knowledge management model | 1 day | ET pillar and HR |
| QC tools in ET pillar implementation | 1 day | ET pillar |
Pack 6 — Initial Phase & Quality Maintenance
Steps 8–9: initial phase management and quality maintenance
Courses: 5 Total: 10 days
| Course | Days | Audience |
|---|---|---|
| Initial Phase Management | 2 day | IM pillar |
| Quality Maintenance | 2 day | QM pillar |
| FMEA | 2 day | Engineering and procurement |
| Statistical quality control (SPC, Cp, Cpk) | 2 day | Quality |
| Design of experiments (DOE) | 2 day | Quality and engineering |
Pack 7 — Office Improvement
Step 10: non-production involvement and office improvement
Courses: 4 Total: 6 days
| Course | Days | Audience |
|---|---|---|
| Non-production involvement in TPM for better plant performance | 1 day | OI pillar |
| Office loss tree workshop | 1 day | Support functions |
| Advanced office 5S | 2 day | Support functions |
| Magikami (roll paper analysis) | 2 day | Support functions |
Pack 8 — Safety and Total Application
Steps 11–12: safety, hygiene, environment, and total application of TPM
Courses: 5 Total: 5 days
| Course | Days | Audience |
|---|---|---|
| Safety, Health and Environment (SHE) | 1 day | SHE pillar |
| Ergonomics | 1 day | SHE pillar and production |
| Safety engineering | 1 day | Engineering and safety |
| TPM step-by-step refreshment / reinforcement | 1 day | Project team |
| How to measure TPM effectiveness | 1 day | Project team and management |