Total Productive Maintenance and Overall Equipment Effectiveness

Programme Summary

This programme helps production and maintenance teams translate equipment losses into coordinated improvement priorities. Participants examine TPM principles, operator care, planned maintenance and supporting organisational practices, then use production data to calculate and interpret overall equipment effectiveness. Applied exercises connect loss analysis with practical actions and ownership, supporting more reliable equipment performance while preserving safe maintenance boundaries and realistic measurement assumptions.

Training Objectives

1 Clarify TPM principles and cross-functional equipment ownership; 2 Strengthen identification and measurement of production losses; 3 Develop reliable interpretation of equipment effectiveness; 4 Connect maintenance and improvement activities with priorities; 5 Plan sustainable equipment performance and competence development.

Learning Outcomes

1 Classify equipment losses using consistent operational definitions; 2 Calculate availability performance quality and overall effectiveness; 3 Identify a justified priority from loss data; 4 Develop safe operator-care and maintenance action proposals; 5 Prepare a practical TPM deployment and monitoring plan.

Target Audience

Maintenance Managers; Production Managers; Maintenance Engineers; Production Supervisors; Reliability Engineers; Continuous Improvement Coordinators.

Target Industries

Food and Beverage Manufacturing; Automotive Components; Packaging Manufacturing; Chemical Processing; Pharmaceutical Manufacturing; Metal Processing.

Course Contents

• Module 1 TPM Purpose and Organisational Participation: Equipment people and production loss reduction; Cross-functional roles and management commitment; TPM pillars and deployment context.
• Module 2 Loss Identification and Data Definitions: Equipment failures setup and minor stops; Speed quality and start-up losses; Consistent event coding and data ownership.
• Module 3 OEE Calculation and Interpretation: Availability performance and quality factors; Planned production time and ideal cycle; Checking denominators assumptions and double counting.
• Module 4 Prioritising Equipment Improvement: Loss Pareto and bottleneck significance; Production impact and constraint relationships; Selecting focused improvement opportunities.
• Module 5 Autonomous Maintenance Foundations: Operator care and abnormality recognition; Cleaning inspection lubrication and basic standards; Authorisation limits and maintenance escalation.
• Module 6 Planned Maintenance Development: Failure history and maintenance prioritisation; Preventive and condition-based task selection; Spare parts planning and work coordination.
• Module 7 Focused Improvement and Problem Solving: Evidence-led analysis of recurring losses; Improvement trials and verification measures; Standardising changes and sharing lessons.
• Module 8 Quality Maintenance and Process Conditions: Equipment conditions influencing product quality; Critical parameters and defect prevention; Checking deterioration and process restoration.
• Module 9 Early Equipment and Product Management: Maintainability reliability and operator access; Learning from existing equipment problems; Commissioning requirements and lifecycle considerations.
• Module 10 Skills Development and Office TPM: Role-based maintenance competence and training; One-point lessons and knowledge transfer; Administrative delays and support-process losses.
• Module 11 Safety Health and Environmental Integration: Safe maintenance boundaries and energy control; Hazard reduction in equipment improvement; Environmental losses and resource efficiency.
• Module 12 TPM Deployment and Performance Review: Pilot equipment selection and staged rollout; Responsibility matrices and review routines; OEE case interpretation and action presentation.

Assessment

• 60 single best answer questions, including applied scenarios; one mark per question.
• 90 minute invigilated digital examination with identity verification. Approved accessibility adjustments preserve the assessed competence.
• Supplied formula sheet and calculator permitted; internet, messaging and AI tools prohibited.
• Individual applied assessment (45 minutes): Calculate OEE from a supplied production dataset, explain its main loss contributors and prepare a focused TPM improvement plan covering operator care, maintenance ownership, safe boundaries and performance verification.
• Assessment criteria: Accurate OEE calculations with transparent data assumptions; Loss-based prioritisation and technically coherent improvement actions; Clear responsibilities safe boundaries and verification measures.
• Pass each component separately: 45/60 written marks (75%) and at least 70% on the applied task.
• All mandatory criteria must pass: Do not propose bypassing safeguards or working with uncontrolled hazardous energy.
• Individual results and feedback are provided. One reassessment may follow coaching under the published enrolment terms.

Certification

• Successful learners receive a TQCSI Arabia digital Certificate of Successful Completion.
• The certificate records the learner name, exact programme title, teaching hours, completion date and unique verification reference.
• Verified identity, full attendance and separate written and applied passes are required; all mandatory critical criteria must be met.
• Proposed issue target: within 30 calendar days of approved results and settlement of applicable fees.
• Records assessed TPM and OEE skills; organisational award status and authorisation to perform maintenance tasks require separate decisions.
• Attendance confirmation may record completed hours for unsuccessful learners; it does not certify successful completion.

Programme Profile

Number of daysNumber of daysNumber of days

333

Total teaching hoursTotal teaching hoursTotal teaching hours

18 hours; breaks, pre course work and formal final assessments excluded.18 hours; breaks, pre course work and formal final assessments excluded.18 hours; breaks, pre course work and formal final assessments excluded.

Delegates allowedDelegates allowedDelegates allowed

Maximum 20 delegates.Maximum 20 delegates.Maximum 20 delegates.

Training prerequisitesTraining prerequisitesTraining prerequisites

Familiarity with production or maintenance operations and basic arithmetic is required. Spreadsheet skills are recommended; maintenance trade competence is not conferred.Familiarity with production or maintenance operations and basic arithmetic is required. Spreadsheet skills are recommended; maintenance trade competence is not conferred.Familiarity with production or maintenance operations and basic arithmetic is required. Spreadsheet skills are recommended; maintenance trade competence is not conferred.

Pre course assignment and assessmentPre course assignment and assessmentPre course assignment and assessment

Complete a 30-minute diagnostic reviewing a supplied production log, downtime categories, output counts and ideal cycle-time assumptions.Complete a 30-minute diagnostic reviewing a supplied production log, downtime categories, output counts and ideal cycle-time assumptions.Complete a 30-minute diagnostic reviewing a supplied production log, downtime categories, output counts and ideal cycle-time assumptions.

End of course assessmentEnd of course assessmentEnd of course assessment

60 question written exam (90 minutes) and individual applied task (45 minutes).60 question written exam (90 minutes) and individual applied task (45 minutes).60 question written exam (90 minutes) and individual applied task (45 minutes).

Passing criteriaPassing criteriaPassing criteria

75% written and 70% applied, passed separately; full attendance. All mandatory criteria must pass.75% written and 70% applied, passed separately; full attendance. All mandatory criteria must pass.75% written and 70% applied, passed separately; full attendance. All mandatory criteria must pass.