Total Productive Maintenance (TPM) Implementation Training Course

Total Productive Maintenance is a structured approach to keeping equipment available, capable, and safe by involving operators in its care rather than leaving everything to a maintenance department. It grew out of lean manufacturing and is built on a small set of pillars and a single guiding measure: overall equipment effectiveness. This course explains how those pieces work and what it takes to put them in place on a real shop floor.

The focus is on implementation, not theory. The course works through the losses TPM targets, how operators and maintenance teams share the work, and how to sequence a rollout so it sticks instead of fading after the launch. It treats TPM as a change in operating habits supported by data, which is where most programs succeed or fail.

Why TPM still matters

Unplanned breakdowns are expensive in ways that go beyond the repair: lost output, scrapped product, missed deliveries, and rushed fixes that create the next failure. Many plants chase these symptoms without addressing the small, repeated losses that quietly erode capacity every shift.

TPM gives those losses a name and an owner. By making operators the first line of equipment care and giving maintenance the time to work proactively, it shifts a plant from reacting to failures toward preventing them. The discipline is decades old, but the problems it solves have not gone away, and digital tools now make the data side easier than ever.

What you will be able to do afterwards

By the end of the course, participants will be able to:

Explain how TPM pillars fit together.
Calculate OEE from availability, performance, and quality.
Interpret OEE component scores to spot weak areas.
Diagnose major equipment losses and target improvements.
Build autonomous maintenance for operator-led equipment care.
Design a phased TPM rollout with roles and metrics.
Apply TPM alongside lean and digital tools.

Course outline

Unit 1: Introduction to TPM

TPM origins in lean manufacturing.
Shift from reactive repair to operator-owned equipment care.
Six big losses versus headline downtime.
Documented TPM adoption case examples.

Unit 2: TPM pillars and frameworks

Eight TPM pillars and their contributions.
5S as a foundation for TPM.
Pillars' links to safety, quality, and training.
Choosing which pillars to start with.

Unit 3: Measuring and improving OEE

OEE availability, performance, and quality components.
Honest OEE calculation, avoiding gamed numbers.
Using OEE to target the biggest loss first.
Mean time between failures and mean time to repair.

Unit 4: Autonomous and planned maintenance

Operator-led cleaning, inspection, and lubrication.
Planned maintenance from time- and condition-based triggers.
Standard work, visual controls, and equipment checklists.
Handing routine care to operators without overload.

Unit 5: Quality and safety in TPM

Quality maintenance and defect prevention at equipment.
Linking equipment condition to product quality.
Safety as an integral part of every TPM activity.
Capturing and acting on near misses during care routines.

Unit 6: Digital TPM and Industry 4.0

Condition monitoring and sensor data for maintenance.
Computerized maintenance management systems.
Where automation supports TPM, covered alongside Automation and Robotics in Manufacturing.
Avoiding dashboards that nobody acts on.

Unit 7: TPM implementation roadmap

Securing leadership commitment and a pilot area.
Sequencing pillars and building capability.
Setting targets and reviewing progress against OEE.
Sustaining the program past initial enthusiasm.

How the course is delivered

The course is led through structured explanation, worked examples, and documented case studies from manufacturing and process plants. Participants work through OEE calculations, loss analysis, and rollout plans and discuss the decisions behind them, then relate each to their own equipment. The course is educational and does not provide certification or assess any plant's operations.

Who should attend

This course suits maintenance and reliability managers, production and operations supervisors, continuous improvement and lean staff, and engineers responsible for equipment performance. It also helps operators stepping into autonomous maintenance roles. No specific prerequisite is required beyond familiarity with a production or process environment.

About EuroQuest International Training

EuroQuest International Training was founded in 2015 by a team with more than 25 years of combined experience in professional training. The institute has delivered over 1,000 courses to more than 15,000 participants, and is headquartered in Bratislava, Slovakia, with training hubs in Dubai, London, Barcelona, Istanbul, Vienna, Paris, and Geneva. Courses are designed and reviewed by practitioners and updated to reflect current practice in each field.

Frequently asked questions

Is TPM only for large factories?

No. The principles apply wherever equipment availability matters, including smaller plants, utilities, and facilities. The course focuses on the method, so you can scale it to the size and complexity of your operation.

How is TPM different from lean or planned maintenance alone?

TPM combines them. It uses overall equipment effectiveness to target losses, gives operators ownership of routine care, and frees the maintenance team to work proactively. The course shows how these elements reinforce each other rather than competing.

Do I need a maintenance background to attend?

No. The course suits production, improvement, and management staff as well as maintenance professionals, because TPM deliberately spreads responsibility for equipment care beyond the maintenance department.

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Register for this course

To reserve a place or ask about scheduling and city options for the Total Productive Maintenance (TPM) Implementation course, use the registration and enquiry options on this page and the EuroQuest team will follow up with the details you need.