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Total Productive Maintenance (TPM) Training Presentation (PowerPoint PPT Deck)

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Format: PowerPoint (PPTX)​

Length: 234 Slides

Terms of Usage

Shift from "I break, you fix" to a culture of collective ownership. This comprehensive 234-slide practitioner toolkit provides the exact framework used by world-class manufacturers to eliminate breakdowns, reduce defects, and maximize equipment effectiveness (OEE).

The Practitioner's Edge: Expert-Led TPM Training

"Operational Excellence is not just about the tools—it is about the mindset of the people using them. As a JIPM-Certified TPM Instructor, Certified Lean Six Sigma Black Belt 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 you drive real, measurable growth through the strategic adoption of TPM and Lean management." — 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

Equipment failure is the silent killer of productivity. Total Productive Maintenance (TPM), a system developed and championed by the Japan Institute of Plant Maintenance (JIPM), provides a structured methodology to achieve "Zero Breakdowns, Zero Defects, and Zero Accidents." This practitioner‑led training resource demystifies the 8 Pillars of TPM and the calculation of Overall Equipment Effectiveness (OEE). By empowering operators to maintain their own equipment through Autonomous Maintenance, organizations can transform their maintenance strategy from a reactive cost center to a proactive competitive advantage.

Key Benefits for Your Organization

  • Maximize Asset Utilization — Dramatically improve your OEE by identifying and eliminating the "Six Big Losses" in your production process.

  • Reduce Maintenance Costs — Transition from expensive, emergency reactive repairs to a disciplined, proactive planned maintenance schedule.

  • Empower the Frontline — Shift the culture toward total employee involvement, where operators take pride in the health and performance of their equipment.

 

According to the U.S. Department of Energy Root Cause Analysis Handbook, RCA is a critical tool for identifying systemic issues and preventing repeat failures across industries—a discipline that is central to the 'Planned Maintenance' and 'Quality Maintenance' pillars of TPM.

Target Audience: Who Is It For?

This toolkit is designed for professionals who need a structured approach to plant-wide improvement:

  • Plant & Operations Managers: For driving a culture of total ownership and equipment reliability.

  • Maintenance Engineers & Technicians: For implementing structured Planned Maintenance systems.

  • Lean & Six Sigma Practitioners: For integrating TPM as a core stability pillar within a Lean transformation.

  • Corporate Trainers: A white-label-ready masterclass to build maintenance capability across multiple sites.

What’s Included in the Box?

  • The Masterclass (230+ Slides): A deep-dive presentation covering the philosophy, 8 pillars, and implementation steps of TPM.

  • TPM Implementation Roadmap & Poster: A visual step-by-step guide to moving from "Model Machine" pilot to plant-wide rollout, including a high-resolution TPM Implementation Poster for shop-floor display.

  • Autonomous Maintenance (AM) Toolkit: Includes the specialized Framework of Autonomous Maintenance and the 7 Steps of Autonomous Maintenance Pillar Poster to guide operator-led equipment care.

  • OEE Calculation Toolkit: Practical guide and example for measuring and analyzing Overall Equipment Effectiveness to identify the "Six Big Losses."

Learning Objectives

By the end of this Total Productive Maintenance (TPM) masterclass, participants will be able to:

  • Interpret the JIPM Framework and understand how the 8 pillars support a zero-loss manufacturing environment.

  • Calculate and Analyze OEE to identify where productivity is being lost due to downtime, speed loss, and quality defects.

  • Implement Autonomous Maintenance (Jishu Hozen) by training operators to perform daily cleaning, inspection, and lubrication.

  • Eliminate the Six Big Losses through structured Planned Maintenance and Focus Improvement (Kobetsu Kaizen).

  • Foster a Culture of Ownership where maintenance and production teams work as a unified force to protect company assets.

Detailed Training Contents

This practitioner toolkit is organized into eight strategic modules:

  • Module 1: Foundations of TPM: History, JIPM standards, and the evolution of maintenance.

  • Module 2: The 8 Pillars of TPM: A detailed walkthrough from Autonomous Maintenance to Safety/Environment.

  • Module 3: Understanding OEE: How to calculate Availability, Performance, and Quality.

  • Module 4: The Six Big Losses: Identifying and attacking the root causes of equipment inefficiency.

  • Module 5: Autonomous Maintenance (AM): The 7 steps to operator-led maintenance excellence.

  • Module 6: Planned Maintenance (PM): Developing a proactive schedule to prevent failures.

  • Module 7: Training & Education: Building the technical skills required for a TPM culture.

  • Module 8: Implementation Strategy: Selecting model machines and scaling the transformation.

Proposed 1-Day Workshop Agenda

This practitioner toolkit is designed to support a high-impact, full-day intensive workshop:

  • 09:00 – 10:30: Introduction to TPM & The JIPM Philosophy.

  • 10:45 – 12:30: Measuring Performance: OEE & The Six Big Losses.

  • 13:30 – 15:30: The 8 Pillars Deep Dive: Autonomous & Planned Maintenance.

  • 15:45 – 16:30: TPM Implementation Roadmap & Pilot Selection.

  • 16:30 – 17:00: Sustaining the Gains & Q&A.

Glossary of Key TPM Terms

  • TPM: A holistic approach to maintenance that focuses on proactive and preventative techniques to improve equipment reliability.

  • OEE (Overall Equipment Effectiveness): The gold standard for measuring manufacturing productivity (Availability x Performance x Quality).

  • Autonomous Maintenance: A process where operators take responsibility for the basic maintenance of their equipment.

  • Six Big Losses: The categories of equipment-related productivity loss: Breakdowns, Setup/Adjustment, Idling/Minor Stoppage, Reduced Speed, Process Defects, and Reduced Yield.

  • Jishu Hozen: The Japanese term for Autonomous Maintenance.

Frequently Asked Questions

  1. Does this follow JIPM standards? Yes, the content is aligned with the Japan Institute of Plant Maintenance methodologies.

  2. Is this deck for manufacturing only? While TPM originated in manufacturing, the principles apply to any asset-heavy environment, including facilities and logistics.

  3. Does it include OEE calculation examples? Yes, the presentation features step-by-step examples for calculating and interpreting OEE.

  4. Is the main deck editable? Yes, it is a fully editable PPTX file that you can customize with your company’s specific branding and examples.

  5. What version of PowerPoint is required? This deck is compatible with all modern versions of Microsoft PowerPoint (Office 365, 2019, 2021).

References

Japan Institute of Plant Maintenance (JIPM) TPM Guidelines; ISO 9001:2015 Quality Management Systems; U.S. Department of Energy Root Cause Analysis Handbook.

About the Author

Allan Ung is the Founder and Principal Consultant at Operational Excellence Consulting (Singapore). As a JIPM-Certified TPM Instructor, 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.

Looking to accelerate your TPM journey?

Go beyond training with our comprehensive document bundle. This toolkit includes editable templates, checklists, and forms designed to support the practical implementation of TPM pillars across your organization.

👉 View TPM Implementation Toolkit

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

 

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