MAPLE TECH SOLUTIONS

Topic: Total Productive Maintenance – Assessment Course

Course Overview:

Total Productive Maintenance (TPM) is the lean tool concerned with maximising the efficiency of
Production Machinery. TPM utilises a team approach to remove the losses from machine areas by
the introduction of autonomous maintenance programmes.

Duration: 20 hrs (08 basics , 12hrs for Assessment Criteria)

What you will learn:

At the conclusion of the course each delegate will be able to:-

• Get their workplace in order ahead of TPM introduction

• Determine the Overall Equipment Effectiveness (OEE) of their machinery

• Understand how to improve the efficiency of their machinery

• Predict where failures are likely to occur

• Be able to design and implement a TPM programme

Course Content

A) The TPM training course covers the following topics:-

• Course Objectives & Definitions

• Getting your workplace in order -5S

• Understanding the basic concepts of TPM - The 8 Key Strategies

• What is Overall Equipment Effectiveness (OEE) and how to measure it

• Understanding the 6 Big Losses and how to address their root causes

• Autonomous Maintenance

• Planned Maintenance

o Time Based Maintenance

o Condition Based Maintenance

• TPM Training

• Early Machine Management

• Quality Initiatives

• Office TPM

Business Transformation consultancy and training services for Industries and SME Organisations
Hosur – 635110, India
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• Safety & TPM

• How to implement TPM

B) TPM Assessment process:

I) Preparation for Assessment – Activity report
One of the main objectives of the TPM activity report is to provide a
record of the TPM activities conducted to date and to allow Assessors
to study carefully prior to commencing the assessment.The report
should not contain audio or video material as this may hinder the
screening process.
(II) Chapter references as per JIPM

Chapter 1 “Outline of Company and Plant” (Refer to page 33 – Example of Content for
Structure Guidelines)

2-1 Company’s/Plant’s Overall Policies and TPM; how they are inter-related 2-2 TPM
Policies, Objectives, Implementation

Chapter 3 “TPM Organizations and Activities”

3-1 History of Equipment Management Organization Evolution 3-2 Status of Plant Organization
and Staffing by Section

3-3 TPM Promotion Organization and Activities

Chapter 4 “Individual Improvement Activities (Kaizen)”

4-1 Outline

Aims, Goals, Concepts and Key Points of Practice

4-2 Structure of Losses and Analysis

4-3 Kaizen Topics; how is being practiced

4-4 Individual Kaizen Examples and Effects

4-5 Results and Future Plans

Chapter 5 “Autonomous Maintenance Activities”

5-1 Outline Aims, Goals and Concepts

5-2 Step-by-Step Implementation and Diagnosis Systems

5-3 Activity Status; Status of each step, activity boards, one point lessens, etc. 5-5
Autonomous Maintenance Examples and Effects

Chapter 6 “Planned Maintenance Activities”

6-1 Outline Features of equipment; issues of equipment maintenance

Business Transformation consultancy and training services for Industries and SME Organisations
Hosur – 635110, India
 MAPLE TECH SOLUTIONS
6-2 Maintenance Department Organization and Staffing

6-3 Role Sharing between Operating Departments and Maintenance Group 6-4 Support for
Autonomous Maintenance
Chapter 7 “Quality Maintenance Activities”

7-1 Outline Aims and Objectives

7-2 Progress and Inspection Methods

7-3 Examples and Effects

7-4 Results and Future Plans

Chapter 8 “Development Management Activities”

8-1 Product Development Management

8-1.1 Outline Concepts, Aims, and Schedule

8-1.2 Designing easy-to-make products in the development stage 8-1.3 Product

Development Management System

Chapter 9 Training and Education

9-1 Basic Concepts and Priority Measures

9-2 Determining Training Budgets

9-3 Outline of training and education and methods to improve skills 9-4 Evaluation of
maintenance work knowledge and skills

Chapter 10 Administration and Other Indirect Departments

10-1 Outline

10-2 Autonomous maintenance activities in administrative and other indirect departments 10-3
Individual improvement (Kaizen) activities in administrative and other indirect departments

10-4 Support for Production Departments

Chapter 11 “Safety, Sanitation and Environment Control”

11-1 Outline

11-2 Objectives

11-3 Organizations and Systems for promotion 11-4 Environmental Protection at work places 11-
5 Activity Status

Chapter 12 “TPM Effect and Evaluation”

12-1 Tangible Effects (List specific equipment and/or the number of machines) 12-1.1 TPM Effect
from overall management viewpoints

12-1.2 TPM Effect on Production (P)

12-1.3 TPM Effect as seen from quality (Q) viewpoints

Business Transformation consultancy and training services for Industries and SME Organisations
Hosur – 635110, India
 MAPLE TECH SOLUTIONS
12-1.4 TPM Effect on Cost (C)

12-1.5 TPM Effect on Delivery (D)

12-1.6 TPM Effect on Safety (S)

12-1.7 TPM Effect from Morale/Training (M) viewpoints 12-2 Intangible Effect

C ) Agenda for Assessment

D) Assessment process – Board room & Gemba (Sch A & B , As per JIPM)
E) Assessment criteria

Methodology:

• Presentation, case studies on relevant industry, Role play and teach back

Who should attend: This course is ideally suited to personnel from Production, Maintenance,
Engineering and Quality?

Clients’ feedbacks:
• The trainer was very knowledgeable about the subject. The examples used were totally
relatable. His explanation was simple and easy to understand. Above all, he was very
patient while clearing doubts and answering questions.
Thank you. I had a great learning experience.

- Paul, Production Manager, Mahendra & Mahendra, India

• Thank you for a great course on TPM Assessment. This is my first time and best experience in
doing online certification. The trainer has presented in a great way and this was far more than
my expectations.
- Karthikeyan R, Manager, Magna Automotive India Pvt Ltd

We provide individual coaching with flexible timings

About the trainer:

• B.E Mechanical and M.S (Mfg mgt) with 28 yrs of experience with major corporate like
JANATICS INDIA, TITAN Industries Ltd, Terumopenpol Ltd, TE Connectivity and Murugappa
group as Head – Mfg and Operational Excellence

Business Transformation consultancy and training services for Industries and SME Organisations
Hosur – 635110, India
 MAPLE TECH SOLUTIONS
• Past 03 yrs running consulancy and training company in name of MAPLE Tech Solutions to
support industries, MSME and Institutions
• Diploma in training from ISTD
• Certified Six sigma black belt from ASQ
• Certified JIPM trainer and consultant for TPM
Our Customers:

Overseas clients:
• Al Ghurair Group, Emerson, Lootah group, saint -gobin– UAE
• Commercial bank of Ethiopia
• Millerbernd Manufacturing Company -USA
• General Motors – Michigan, USA
• Weigel - USA

D Eregamani
Founder & Director
MAPLE Tech Solutions
India
Email: sudhaeregamani@gmail.com

Business Transformation consultancy and training services for Industries and SME Organisations
Hosur – 635110, India