This course aims at introducing Total Productive Maintenance (TPM) at the beginner’s level where we will talk about the history and evolution of TPM, differentiating it from Total Quality Management. We will discuss about different Productive Maintenance (PM) Systems used for the maintenance activities in the organizations with examples and the success stories and also about the difficulties in implementing TPM. Thus, the participants will be able to appreciate TPM as a corporate culture that not only prevents losses, but effectively involve everyone from top management to workers to actively participate in small groups and acts as the key to maximize company-wide productivity.
By the end of this course, participants will be able to:
Describe TPM as a distinct approach to conventional maintenance practices which optimizes equipment effectiveness by eliminating breakdowns
Explain how TPM has revolutionized the maintenance
Appreciate the basic objective of TPM which seeks to create a sense of joint responsibility between supervision, operators and maintenance workers in order to keep the machines and equipments working smoothly and to optimize their overall performance
Describe the famous 8 Pillars of TPM, their benefits and implementation
Explain the common features of the workplace with poor TPM practices and about different types of TPM losses and their causes and the barriers which are there in the process of implementation of TPM
Explain the steps involved in effective implementation of TPM
List the use of autonomous maintenance as a strategic tool in maintenance wherein the operator performs day-to-day activities pertaining to his area of work by himself and how the Autonomous maintenance facilitates cultural change.
Describe how TPM optimizes the availability of process machinery, reduces the cost of maintenance and provides the means to improve quality, productivity and profitability of manufacturing plants
List different TPM education methods and about the Tools Management System and how to measure the goals and effectiveness of TPM using the Overall Equipment Effectiveness (OEE) ratio.
Course Status :
Course Type :
Credit Points :
Start Date :
31 Jan 2023
End Date :
30 Apr 2023
Enrollment Ends :
15 Mar 2023
Exam Date :
Module 1: “Introduction to TPM”
Case Study:NIKE’S 2001 PLANNING SYSTEM PERPLEXITY
What does PM means?
PM as a Postponed Maintenance
What is TPM?
What does TPM stands for?
History of TPM
Difference between TQM & TPM
Need of TPM in organization
Principles of TPM
TPM-A Zero sum game
Goals and objectives of TPM
Difficulty in implementation of TPM
The TPM Paradigm Shift
TPM is a team effort
Expectation from TPM
Roles and Responsibilities in TPM
The Operators role
The Specialists role
Improvement teams role
Module 2: TPM pillars
TPM-8 pillars Introduction
Pillar 1: Autonomous maintenance (JishuHozen)
Pillar 2: Focused Improvement (Kobetsu Kaizen)
Pillar 3: Planned Maintenance
Pillar 4: Quality Maintenance
Pillar 5: Early Equipment Maintenance
Pillar 6: Education and Training
Pillar 7: Safety, health And Environment
Pillar 8: Office TPM
Module 3: Maintenance under TPM
Goals & objectives of autonomous maintenance
7 Steps to autonomous maintenance
Step-1: Initial clean-up using 7S system
Step-2: Repair sources of defects
Step-3: Develop standards & data collection
Step-4: Standards for monitoring key process parameters
Step-5: Train operators on function & troubleshooting
Step-6: Provide spare parts &tools orderliness
Step-7: All out autonomous maintenance
Goals and objectives of breakdown maintenance
3 Steps to standardized breakdown work
Step-1: Identify root cause
Step-2: Eliminate cause
Step-3: Standardize preventive work to eliminate reoccurrence
Transition of breakdown maintenance to preventive maintenance
Module 4: Maintenance under TPM (contd.)
Goals and objectives
7Steps of planned maintenance
Step-1: Support to ‘Autonomous Maintenance’ activities
Author RalphL., Kliem(2013)“Creative, Efficient and Effective Project Management,CRC Press
Author William Lewis,1998“PDCA/Test”, CRC Press
Dr. Anil Kumar Srivastava
Dr. Anil K. Srivastava is a retired as Professor of Statistics from the University of Lucknow. He is well known across the wide spectrum of industries and institutions of higher education in India and abroad for establishing the subject Quality Management as an academic discipline at post graduate level. He was one of the founding Directors of the Quality Management program under the aegis of which the University of Lucknow started a Masters level degree course, viz. Master of Total Quality Management (MTQM).
Having obtained his Master’s and Doctoral Degree in Statistics, Dr. Srivastava has widely published in Econometrics, Regression Analysis & Forecasting and in Statistical Inference. He has supervised more than 600 projects related to the field of Quality Management in various sectors of industries.
Dr. Srivastava has been closely associated with Quality Council of India (QCI) in its various endeavours for a long time and has been appointed as its Principal Advisor. Currently Dr. Srivastava lectures on various aspects of Total Quality Management (TQM) and Total Productivity Management (TPM) .
He is also the Director of the Institute of Applied Statistics & Quality Management (IASQM) at Lucknow and is an Executive Member of CIIs (Confederation of Indian Industries) Uttar Pradesh State Council.
Type of exam: Computer based exam
You will have to appear at the allotted exam centre and take the exam in person.
You can find the final allotted exam centre details in the hall ticket.
Type of questions may include multiple choice questions, fill in the blanks, essay type (subjective) type, etc. But, generally MCQs are most common type of questions.
Weightage: 25% weightage for weekly assignment + 75% weightage for final exam.
Passing Marks: You will be eligible for Certificate only if you score minimum 40% in Weekly Assessment and minimum 40% in Final Exam.