A New Direction In Production Towards Zero Defect
Duration: 2 Days

The demand for high quality products at lower costs is driving manufacturers to shift focus toward equipment management programs. Leading the way is the Japanese theory known as Total Productive Management (TPM), a proactive equipment maintenance strategy designed to improve overall equipment effectiveness. In today’s manufacturing world, maintenance costs represent from 15% to 70% of total production costs.

Through TPM, manufacturers can stop accepting the inevitability of high maintenance costs and begin lowering production costs. This is achieved by evaluating overall equipment effectiveness and implementing TPM programs aimed at Zero Defects and Zero Failures.

The goal of TPM is to increase the productivity and life cycle of equipment with a team approach that involves engineering, maintenance and operations personnel.

• Prevent breakdowns of equipment
• Eliminate minor stoppages
• Minimize production defects
• Reduce maintenance costs
• Reduce set-up and adjustment losses
• Maximum line speed
• Decrease start-up losses

Lectures, group exercise and presentation

• Production, Maintenance and Engineering Personnel who must work together to achieve
their goals.
• Participation from other areas, e.g. Finance and Administration is also recommended
because TPM is based on the power of cooperation.

This workshop must be attended if your manufacturing operations need to become more responsive to your customer’s needs. You will be introduced to the many concepts that fall under the umbrella of lean manufacturing, more so you will also get tangible ideas that you can take back to work and implement. For example, you will learn how to reduce cycle time and how to use workflows to develop effective and efficient plant layouts. In addition, you will discover how cellular operation concepts can increase your productivity and deliver results that will enhance your bottom line.



  1. Introduction – The Power of TPM
  2. 2. TPM Defined
    a) History of TPM
    b) Preventive Maintenance and TPM
    c) The 5 Pillars of TPM
    i.   Implement improvement activities
    ii.  Establish autonomous maintenance
    iii. Establish a planned maintenance system
    iv. Establish training courses
    v.  Establish a system for MP design and early equipment management
    d) TPM and Product Quality
  3. Equipment Condition Analysis
  4. Major Causes of Breakdowns and Defects
  5. Characteristics and Goals of TPM
    a) 3 Principles of Prevention
    b) 2 Main Goals of TPM
    c) 8 Fundamental Development Activities of TPM
  6. Eliminating Equipment Losses
    a) The 6 major Losses
    i. Breakdown Losses
    ii. Setup and adjustment losses
    iii. Idling and minor stoppage losses
    iv. Reduced speed losses
    v. Quality defects and rework
    vi. Startup / yield losses
  7. Thinking Systematically For Equipment Performance Improvement


  1. Where to start TPM – A Feasibility Study
  2. Measuring Equipment Effectiveness
  3. Autonomous Maintenance Program
    a) What and Why a Autonomous Program?
    b) A 7-step Program for AMP
  4. Key TPM Strategies
  5. Preparation and Implementation of TPM
    a) A 12-step implementation Program

Program Code: 2-1000-03