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TPM Education & Training (E&T) Pillar Presentation & Toolkit (PowerPoint PPT Deck)

Format: PowerPoint (PPTX)​

Length: 111 Slides

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Shift from reactive, ad-hoc training to a systematic, data-driven skill development system that empowers your frontline and satisfies JIPM criteria.

The Practitioner's Edge

"Operational Excellence is not just about the tools—it is about the mindset of the people using them. As a JIPM-Certified TPM Instructor, TWI Master Trainer, and Certified Management Consultant who has led transformation initiatives at Microsoft, IBM, and Underwriters Laboratories (UL), I have built this toolkit to be more than just a presentation. It is the distilled logic of years spent on the 'Gemba,' designed to help your team build a self-sustaining training system, deploy visual Skills Matrix Boards, and secure your JIPM TPM Excellence Award." — Allan Ung, Principal Consultant at OEC Singapore

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Global Impact: OEC’s training toolkits have been utilized by managers and practitioners across Asia, Europe, and North America to build Lean capability and drive organizational improvement.

Executive Summary

Unskilled operators are the silent drivers of chronic equipment breakdowns, defects, and speed losses. This comprehensive TPM Education & Training (E&T) Practitioner Toolkit provides the exact operational framework required to establish a robust, JIPM-aligned system for developing human resources. Aligned directly with the official Japan Institute of Plant Maintenance (JIPM) Checklist C (Category 7) assessment criteria and the OEC TPM Maturity Diagnostic, this toolkit shows you how to upgrade operator and maintenance skills systematically.

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By leveraging proven workplace instruction methodologies like the Training Within Industry (TWI) 4-Step Job Instruction (JI) method, this deck demystifies how to design Training Timetables, build visual Skills Matrix Boards, and cascade peer-to-peer One-Point Lessons (OPLs). It bridges the gap between classroom theory and shopfloor reality, helping your plant transition from reactive training to a self-managing, world-class learning ecosystem.

Key Benefits for Your Organization

  • Secure JIPM Award Compliance — Directly satisfy the "system for developing human resources" prerequisite and Category 7 audit criteria across all award tiers.

  • Eliminate Loss-Driving Skill Gaps — Trace the Six Big Losses (such as breakdowns, minor stoppages, and quality defects) straight to root-cause skill gaps and deploy targeted E&T responses.

  • Visual Work Management — Establish highly visible shopfloor Skills Matrix Boards and 4-quadrant skill maps to eliminate tribal knowledge.

  • Build an On-the-Job (OJT) Delivery Dojo — Design standardized training timetables and use the TWI JI card to guarantee that "if the worker hasn't learned, the instructor hasn't taught".

  • Drive Autonomous & Planned Maintenance — Equip operators with 5-senses inspection skills and help maintenance technicians scale their capabilities from Time-Based (TBM) to Condition-Based Maintenance (CBM).

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As highlighted by the Japan Institute of Plant Maintenance, Education & Training (E&T) is a critical pillar for building the skills that make every other pillar work.

Target Audience: Who Is It For?

This toolkit is purpose-built for manufacturing leaders committed to achieving world-class operational excellence:

  • TPM Promotion Office Leads & Steering Committees seeking to draft and format Chapter 9 of the TPM Activity Report for JIPM assessors.

  • E&T Pillar Leaders responsible for designing, deploying, and tracking skill development systems across operations.

  • Plant Managers & Operations Directors looking to eliminate "pillar consistency gaps" and build an audit-ready baseline.

  • Corporate Trainers & OJT Instructors requiring a white-label-ready masterclass to build shopfloor competency.

What’s Included in the Box?

  • The Masterclass Presentation (110+ Slides): A deep-dive curriculum divided into 8 modules covering foundations, losses, JIPM criteria, skills matrix, TWI, AM/PM enablement, supervisory leadership, and award readiness.

  • The E&T Maturity Diagnostic: A rigorous, 5-dimension assessment rubric mapping maturity from Foundational to World-Class, complete with the peer-pillar protocol.

  • TWI 4-Step JI Training Aids: Structured cards and templates to facilitate standard workplace instruction.

  • One-Point Lesson (OPL) Visual Standard: Guidelines and mockups for creating Basic Knowledge, Problem, and Improvement lessons.

Learning Objectives

By the end of this 8-module curriculum, participants will be able to:

  • Explain why E&T is the pillar every other TPM pillar depends on, and locate its position in JIPM's assessment framework.

  • Trace the Six Major Losses (Availability, Performance, and Quality) to the specific skill gaps that drive them.

  • Read and apply JIPM's E&T checklist criteria (Checklist C, B, A, S) across all five award categories.

  • Build and maintain a visual skills matrix board using the 4-quadrant competency system, Training Timetables, and OPLs.

  • Apply the TWI 4-Step Job Instruction method and Job Breakdown Sheets (JBS) to train any physical or special-case skill.

  • Demonstrate how the E&T pillar enables Autonomous Maintenance (AM Step 4) and Planned Maintenance (PM Steps 1-3) execution.

  • Utilize analytical tools (5-Why, ECRS, 4M) and TWI Job Relations (JR) to support supervisory leadership and sustain trained performance.

  • Score E&T maturity with the 5-dimension diagnostic and plan JIPM award-submission readiness.

Detailed Training Contents

  • This practitioner toolkit is organized into eight strategic modules:

  • Module 1 — Foundations of the E&T Pillar: The 8 pillars of TPM; prerequisite criteria; the TWI motto; three priority measures; 4 levels of maturity; and four audiences (operators, technicians, engineers, managers).

  • Module 2 — The 6 Major Losses & the Skill Gaps Behind Them: The OEE framework; breakdown and setup/adjustment losses; minor stoppage and speed losses; defect/rework and startup/yield losses; Loss -> Gap -> E&T Response mapping; JIPM Achievement Sheet indicators (Productivity, Quality, Cost, Delivery, Safety, Morale).

  • Module 3 — JIPM E&T Assessment Criteria Deep-Dive: The 5 award tiers; Category 7 checkpoint escalation (C, B, A, S); KMI (competency indices), KPI (instructor counts), KAI (OPL updates) metrics; and Self-Checklist scoring mechanics.

  • Module 4 — Building the Skills Matrix: Visual skill progress circle system (Empty to Full circle); designing a Skills Matrix Board; training timetable triggers (new equipment, poor line performance, turnover); OPL visual policies; and the OPL cascading method.

  • Module 5 — Designing the Training System (TWI Job Instruction): Why telling/showing alone fails; TWI JI 4 Steps (Prepare, Present, Try-Out, Follow Up); Job Breakdown Sheets (Important Steps, Key Points, Reasons); special instruction challenges (long operations, noise, "feel"); and strategic training budget determination.

  • Module 6 — E&T Enabling AM & PM Execution: AM Step 4 (General Inspection Skills Training); 5-senses inspection and visual controls; PM support bridge (PM Steps 1-3 training AM operators); and the PM Step 6 CBM skill ladder.

  • Module 7 — E&T Enabling FI, QM & Supervisory Leadership: Focused Improvement analytical toolkit (Cause & Effect, 5-Why, P-M Analysis); TWI JM 4-Step ECRS method (Eliminate, Combine, Rearrange, Simplify); Quality Maintenance 4M conditions; TWI Job Relations 4 Foundations and the 4-Step JR method.

  • Module 8 — Sustaining, Measuring & Award Readiness: The 5 evaluation dimensions (Needs Assessment, Skills Visibility, Dojo Infrastructure, Qualification, and Business Impact); OEC peer-pillar protocol and shopfloor walks; TPM Activity Report Chapter 9 "Line 3 Zero Minor Stoppages" case study; and future roadmap planning.

Proposed 1-Day Workshop Agenda

This toolkit is designed to support a full-day intensive workshop. A typical high-impact schedule includes:

  • 09:00 – 10:30: Foundations of E&T, Priority Measures, and JIPM Assessment Criteria (Modules 1-3).

  • 10:45 – 12:30: Building the Skills Matrix Board and Designing the OJT TWI System (Modules 4-5).

  • 13:30 – 15:30: Cross-Pillar Integration: Enabling AM, PM, FI, and QM Execution (Modules 6-7).

  • 15:45 – 17:00: Measuring Maturity, Chapter 9 Case Study Drafting, and JIPM Award Submission Readiness (Module 8).

Glossary of Key Terms

  • TWI Job Instruction (JI): A systematic four-step training method (Prepare, Present, Try-Out, and Follow Up) used by supervisors and instructors to deliver rapid, error-free skill transfer, guided by the principle that "if the worker hasn't learned, the instructor hasn't taught".

  • Job Breakdown Sheet (JBS): An instructor’s personal preparation document that organizes the operation in their mind by dividing a task into Important Steps (what advances the work), Key Points (safety, quality, or "knacks"), and Reasons (why it must be done that way). It is strictly used as an instructor’s guide and is never handed to the learner.

  • One-Point Lesson (OPL): A brief, five-to-ten minute, highly visual training tool focused on a single theme that fits entirely on a single page. OPLs are categorized into three types: Basic Knowledge, Examples of Problems, or Examples of Improvements.

  • Skills Matrix Board: A visual shopfloor grid displaying operator names on the vertical axis and required process or equipment skills on the horizontal axis, tracking competency using a four-quadrant progress circle to identify organizational skill gaps at a glance.

  • Training Timetable: A scheduled, dated who/what/by-when training commitment deployed by supervisors to strategically plan skill development rather than scheduling sessions based on random calendar openings.

  • Key Management Indicators (KMIs): High-level, boardroom outcome metrics tracked on the JIPM Achievement Sheet, such as the plant's overall multi-skilling rate percentage and the workforce competency index.

  • TWI Job Methods (JM): An analytical four-step improvement methodology that applies the ECRS (Eliminate, Combine, Rearrange, Simplify) technique to help Focused Improvement teams optimize current work methods.

  • TWI Job Relations (JR): A leadership framework that teaches supervisors how to treat workers as individuals to prevent people problems and sustain a highly motivated and trained workforce.

Frequently Asked Questions (FAQs)

  1. What is the fundamental difference between a standard HR training plan and the TPM E&T Pillar? An annual HR training calendar is typically built around individual employee career development plans. In contrast, the TPM E&T pillar is systematically designed to identify and close specific, nameable competency gaps that are actively costing the plant availability, performance, or quality.

  2. How does JIPM’s four-quadrant skills circle track shopfloor competency? Instead of recording mere classroom attendance, the circle verifies progressive capability: an empty circle means no training, one quadrant denotes completed theory, two quadrants mean performance under supervision, three quadrants mean independent performance, and a full circle certifies the operator to instruct others.

  3. What specific triggers dictate when to schedule a Training Timetable? A systematic E&T system only schedules a Training Timetable in response to three triggers: the commissioning of new equipment, poor line performance tracing back to a workforce skill gap (such as minor stoppages), or personnel turnover that threatens the loss of uncaptured tribal knowledge.

  4. What is an "orphan OPL" and how does the E&T framework eliminate it? An "orphan OPL" is a well-designed lesson created to satisfy a training quota but completely disconnected from an actual gap on a skills matrix board. The OPL cascading method eliminates this by requiring teams to first identify a matrix gap, then research, draft, present, and track attendance directly on the shopfloor.

  5. How does the E&T Pillar directly support Autonomous Maintenance (AM) execution? E&T is the engine for AM Step 4 (Conduct General Inspection Skills Training). It provides structured, peer-to-peer training in technical areas like pneumatics, hydraulics, lubrication, drive systems, and safety using five-senses inspection and visual controls.

  6. How do Planned Maintenance (PM) technicians function within the E&T delivery system? During the first three steps of PM, technicians act as instructors to AM operators, explaining machine functions, normal-versus-abnormal conditions, red-and-white tagging, and teaching them how to draft their own One-Point Lessons.

  7. Why does traditional "telling" or "showing" alone fail as an effective training method? Telling alone fails because verbal descriptions cannot capture tactile "feel," timing, or safety hazards. Showing alone allows learners to mimic physical motions without understanding the underlying principles or "reasons why," which eventually leads to defects and minor stoppages.

  8. How does E&T ensure complete traceability from boardroom outcomes to shopfloor actions? E&T coordinates metrics across a three-tier model: Key Management Indicators (KMIs) at the boardroom level, Key Performance Indicators (KPIs) in the middle (e.g., instructor counts, training hours), and Key Activity Indicators (KAIs) on the shopfloor (e.g., updated boards and OPL sign-offs).

References

  • Japan Institute of Plant Maintenance (JIPM). TPM Excellence Award Assessment Criteria and Guidelines.

  • Training Within Industry (TWI) Institute. Job Instruction, Job Methods, and Job Relations standard curricula.

  • Operational Excellence Consulting (OEC) TPM Maturity Diagnostic Repository.

About the Author

Allan Ung is the Founder and Principal Consultant at Operational Excellence Consulting (Singapore). As a Certified Lean Six Sigma Black Belt and Certified Management Consultant (CMC, Japan) with a career spanning leadership roles at Microsoft and IBM, Allan specializes in driving transformative growth by maximizing customer value and minimizing waste. His practitioner-led approach bridges the gap between high-level strategy and shop-floor execution.

 

These facilitation-ready training toolkits are distilled from decades of real-world practice. Used by organizations across Asia, Europe, and North America, they are designed to help professionals move from awareness to successful implementation.

Further Learning Resources

Operational Excellence Consulting offers a full catalog of facilitation‑ready training presentations and practitioner toolkits covering Lean, Design Thinking, and Operational Excellence. These resources are developed from real workshops and transformation projects, helping leaders and teams embed proven frameworks, strengthen capability, and achieve sustainable improvement.​

 

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👉 Browse our full library of facilitation‑ready toolkits, designed to support leaders and teams across Lean, Design Thinking, and Operational Excellence: www.oeconsulting.com.sg

📖 Deep-Dive: Read the Practitioner's Guide

Deepen your understanding of the visual Skills Matrix Board, the TWI Job Instruction engine, and how to eliminate "orphan OPLs" to build a self-sustaining training system.

👉 Read the TPM E&T Practitioner Guide

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