Total Productive Maintenance (TPM) and Cost-Efficient Operations Training Course
1Summary
Poor maintenance planning rarely announces itself with a single dramatic failure — it shows up gradually, as rising repair bills, unplanned downtime, and equipment that never quite reaches its rated capacity. Organizations that treat maintenance as an afterthought end up paying for it through lost production, safety incidents, and shortened asset life. The alternative is a maintenance function that is planned, measured, and tied directly to business goals rather than run reactively.
This Arab British Fellowship Training Academy training course walks participants through Total Productive Maintenance (TPM) as a practical strategy: how to plan and control maintenance costs across a project's full lifecycle, how self-maintenance shifts routine care to the people who operate the equipment every day, and how planning tools such as PERT networks keep repair and maintenance work on schedule. The goal is equipment that stays in top condition, output that meets quality targets, and a maintenance budget that stays under control.
2Objectives and target group
Course Objectives
- Build a maintenance strategy that ties equipment capacity, product quality, and safety directly to overall business performance.
- Apply Total Productive Maintenance (TPM) concepts, including its characteristics, costs, and implementation stages.
- Use self-maintenance principles to give equipment operators a direct role in day-to-day upkeep.
- Plan and monitor maintenance and repair work using scheduling tools such as PERT networks.
- Build a full costing system for maintenance and repair, including spare parts and raw material economics.
- Diagnose recurring maintenance problems and draft practical, cost-aware solutions.
Who Should Attend?
- Engineers, technicians, contractors, and consultants working in planning, design, construction, or operations.
- Those responsible for electrical maintenance within facility distribution networks.
- Staff working across industrial networks.
- Inspectors, safety officers, and supervisors.
3Course Content
Module 1: Why Traditional Maintenance Plans Fall Short
- The importance and policy of maintenance within the overall business strategy.
- How maintenance affects equipment capacity, product quality, safety, and production costs.
- Maintenance as a driving factor in technology selection.
Module 2: Total Productive Maintenance (TPM) in Practice
- What integrated productive maintenance means and its main distinguishing characteristics.
- Why, when, and how to implement TPM, and its associated costs and penalties.
Module 3: The Operator's Role and Self-Maintenance
- The meaning, benefits, and practical application of self-maintenance.
- The operator's duties and integrating self-maintenance with the other pillars of TPM.
- Common difficulties in implementing self-maintenance and how to work around them.
Module 4: Planning and Controlling Maintenance Work
- Planning programs and control procedures using business networks (PERT).
- Methods for anticipating and identifying faults before they escalate.
- Organizing maintenance work to improve operating quality, and addressing project completion and update problems.
- Stating maintenance problems clearly and drafting workable solutions.
Module 5: The Economics of Maintenance Management
- The economic results of applying structured maintenance systems.
- Building a comprehensive costing system for maintenance and repair.
- The economics of preserving spare parts and raw materials.
- The technical and economic case for establishing dedicated maintenance and repair workshops.