Sunday 9 December 2018

TPM Training (Total Productive Maintenance)

Total Productive Maintenance (TPM) is an all-inclusive approach to equipment maintenance that strives to achieve perfect production (zero defects).  TPM is a concept with the aim to maximize the productivity of facilities by transferring the responsibility for regular maintenance to employees.

The operator's ability to maintain engine performance. who has a long experience for the application of TPM in the operational area of ​​the factory.

Stages of Training

  1. Do not know.

  2. Know the theory but cannot do.

  3. Can do but cannot teach Phase

  4. Can do and also teach.

How to define Policy?

  • Focus on improvement of knowledge, skills and techniques.

  • Creating a training environment for self-learning base on felt needs.

  • Training curriculum / tools /assessment etc conductive to employee revitalization

  • Training to remove employee fatigue and make work enjoyable.

What can be Goals?

  • Achieve and sustain downtime due to want men at zero on critical machines.

  • Achieve and sustain zero losses due to lack of knowledge / skills / techniques

  • Aim for 100 % participation in suggestion scheme.


TPM is a method of repair that involves all employees in order to improve the care of machines, equipment and increase productivity. The goal is to improve the efficiency of the machine and the causes. Such as downtime, change-over, idle, defects and rework (see 7 Deadly Waste in factory operations).

The purpose of training is to understand the philosophy, strategies and tools of the TPM and control approach to improve the effectiveness of the overall machinery and equipment.
This training was attend by staff and managers associate with production and maintenance companies.

TPM as part of Lean Manufacturing methods are proves to be effective in improving the performance of the engine, increasing the lifetime of the engine, and saving the cost of maintenance. With the application of 8 pillars of TPM, the ability to maintain the performance and keep the 'health' machine will increase, so that they can perform minor repairs if they occur in the machine.

"TPM provides capabilities and operators to maintain quality performance with effective and efficient engines.

Other participants from the Komatsu add. " The TPM gives training and open horizons of knowledge about the importance of independent care on a production machine."

TPM Program training

A TPM program brings maintenance into focus as a necessary and vitally important part of the business. This also provides a methodology to control down time for maintenance. As a part of the manufacturing day and, in some cases as an integral part of the manufacturing process without avoid safety and environmental consideration.

Training Process

It is aim to have multi-skill revitalize employees whose morale is high and who has eager to come to work and perform all require functions effectively and independently. Education can give to operators to upgrade their skill. It is not sufficient know only "Know-How" by they should also learn "Know-why". By experience they gain, "Know-How" to overcome a problem what to be complete.

This they do without knowing the root cause of the problem and why they are doing so. Hence it become necessary to train them on knowing "Know-why". The employees should be train to achieve the four phases of skill. The goal is to create a factory full of experts. The different phase of skills is:

Steps in Educating and training activities:

  • Setting policies and priorities and checking present status of education and training.

  • Establish of training system for operation and maintenance skill up gradation.

  • Training the employees for upgrading the operation and maintenance skills.

  • Preparation of training calendar.

  • Kick-off of the system for training.

  • Evaluation of activities and study of future approach.

The goal is to hold emergency and unscheduled maintenance. To a minimum in order to achieve a target for equipment effectiveness. A company-wide preventive maintenance includes; employee, autonomous maintenance drives.

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