Introduction
This Lean Maintenance & Total Productive Maintenance training course develops the practical capability to improve equipment reliability, eliminate maintenance waste and create greater ownership of asset performance across operations and maintenance teams. Lean Maintenance applies lean principles to maintenance processes, while Total Productive Maintenance (TPM) creates a structured approach to preventing equipment losses and improving Overall Equipment Effectiveness (OEE). Together, they provide a powerful framework for improving reliability, productivity and maintenance performance.
The training course progresses from Lean and TPM fundamentals to maintenance process improvement, equipment-loss analysis, autonomous maintenance, planned maintenance and reliability improvement. Participants will examine OEE, the Six Big Losses, workplace organisation, preventive and predictive maintenance, root-cause analysis and maintenance performance indicators. The second part of the course focuses on defect elimination, operator-maintainer collaboration, continuous improvement, TPM implementation and sustaining results. Participants will leave with a structured approach for developing a Lean Maintenance and TPM improvement roadmap within their organisations.
This Lean Maintenance & Total Productive Maintenance training course will highlight:
- Applying Lean principles to maintenance processes and workflows
- Using TPM to improve equipment reliability and ownership
- Measuring OEE and eliminating major equipment losses
- Strengthening autonomous, planned and condition-based maintenance
- Applying structured problem-solving to recurring equipment failures
- Building a sustainable Lean Maintenance and TPM improvement system
Objectives
By the end of this training course, participants will be able to:
- Apply Lean principles to identify and eliminate maintenance waste.
- Evaluate equipment performance using OEE and loss analysis.
- Develop autonomous and planned maintenance practices using TPM principles.
- Apply reliability and root-cause techniques to recurring equipment problems.
- Establish maintenance KPIs and continuous improvement processes.
- Develop a structured roadmap for Lean Maintenance and TPM implementation.
Training Methodology
This training course combines expert-led presentations, maintenance examples, equipment-performance analysis, structured problem-solving and improvement exercises. Participants will examine maintenance workflows, OEE data, equipment losses, recurring failures and maintenance performance indicators. Practical applications will connect Lean tools with TPM, reliability and continuous improvement principles. The methodology emphasises measurable equipment improvement and stronger collaboration between maintenance and operations.
Organisational Impact
Organisations will benefit from:
- Reduced maintenance waste and process inefficiency
- Improved equipment availability and OEE
- Fewer recurring failures and unplanned stoppages
- Stronger operator and maintenance collaboration
- Better use of preventive and condition-based maintenance
- More sustainable continuous improvement in asset performance
Personal Impact
Participants will develop:
- Stronger understanding of Lean Maintenance and TPM
- Improved capability in identifying maintenance waste
- Greater confidence in OEE and equipment-loss analysis
- Practical skills in autonomous and planned maintenance
- Better root-cause and reliability problem-solving capability
- Improved ability to lead maintenance improvement initiatives
Who should Attend?
This training course is designed for professionals directly responsible for maintenance, reliability and equipment performance, including:
- Maintenance Managers and Supervisors
- Maintenance Engineers
- Reliability Engineers
- Mechanical and Electrical Maintenance Engineers
- Condition Monitoring Professionals
- Maintenance Planners and Schedulers
- Asset Reliability Professionals
- Production and Operations Supervisors responsible for equipment performance
- TPM and Continuous Improvement Professionals
- Maintenance Excellence Professionals
Lean Maintenance & TPM Fundamentals
- Principles of Lean thinking in maintenance
- Understanding value and waste in maintenance
- Lean Maintenance versus traditional maintenance
- Fundamentals and objectives of TPM
- Maintenance contribution to operational performance
- Building the foundation for maintenance excellence
Maintenance Waste & Process Improvement
- Identifying the major wastes in maintenance
- Mapping maintenance processes and workflows
- Identifying delays, bottlenecks and non-value-added work
- Applying 5S to maintenance workplaces
- Improving tools, materials and information availability
- Standardising efficient maintenance processes
Overall Equipment Effectiveness & Equipment Losses
- Understanding availability, performance and quality
- Calculating Overall Equipment Effectiveness (OEE)
- Understanding the Six Big Losses
- Identifying equipment-related performance losses
- Establishing equipment-performance baselines
- Prioritising improvement opportunities using loss data
Autonomous Maintenance
- Principles and objectives of autonomous maintenance
- Developing operator ownership of basic equipment care
- Cleaning, inspection and lubrication practices
- Identifying abnormalities and deterioration
- Establishing visual controls and operating standards
- Developing autonomous maintenance implementation steps
Planned Maintenance & Work Management
- Developing an effective planned maintenance system
- Preventive versus corrective maintenance strategies
- Selecting appropriate maintenance intervals
- Planning and scheduling maintenance work
- Managing maintenance backlog and priorities
- Improving schedule compliance and work execution
Condition-Based & Predictive Maintenance
- Principles of condition-based maintenance
- Selecting equipment for condition monitoring
- Vibration, lubrication and temperature monitoring
- Using inspection and condition data effectively
- Establishing condition alerts and intervention criteria
- Integrating predictive maintenance with planned work
Reliability Improvement & Defect Elimination
- Understanding equipment failure patterns
- Distinguishing symptoms, failure modes and causes
- Applying Pareto analysis to recurring failures
- Using the 5 Whys and cause-and-effect analysis
- Developing corrective and preventive actions
- Establishing a defect-elimination process
Focused Improvement & Maintenance Optimisation
- Principles of focused improvement within TPM
- Selecting high-value improvement opportunities
- Improving maintainability and maintenance accessibility
- Reducing maintenance and equipment downtime
- Optimising spare parts and maintenance resources
- Verifying and sustaining improvement results
Maintenance Performance, People & TPM Culture
- Selecting meaningful maintenance KPIs
- MTBF, MTTR, availability and schedule compliance
- Developing maintenance performance dashboards
- Strengthening operator-maintainer collaboration
- Building skills and ownership for equipment reliability
- Developing a continuous improvement culture
Lean Maintenance & TPM Implementation
- Assessing Lean Maintenance and TPM maturity
- Identifying implementation priorities and gaps
- Establishing TPM roles and responsibilities
- Developing implementation phases and milestones
- Monitoring benefits and sustaining improvements
- Developing a Lean Maintenance and TPM roadmap
- Upon successful completion of this training course, GLOMACS Certificate will be awarded to the delegates. Continuing Professional Education credits (CPE): In accordance with the standards of the National Registry of CPE Sponsors, one CPE credit is granted per 50 minutes of attendance
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