TPM
Training Malaysia
From breakdown-reactive to zero-breakdown — with operators who own their machines.
100% HRDC Claimable — All programmes delivered by an HRDC Accredited Trainer. Fully claimable under the SBL-Khas scheme. We assist with documentation and grant application.
Get a Training Proposal →What This Programme Covers
Total Productive Maintenance is frequently misunderstood as a maintenance department programme. It is not. TPM is a production system in which operators take primary responsibility for their equipment's basic condition — and maintenance engineers focus on the complex failures that operators cannot handle. This program builds both sides of that equation: operator autonomous maintenance skills (the 7 steps), and the maintenance engineering systems (planned maintenance, predictive tools, and MTBF/MTTR improvement) that support zero-breakdown production.
If your main issue is unstable output, recurring stops, bottlenecks or missed daily production targets, TPM should be connected to a wider production line improvement plan rather than treated as a maintenance-only course.
What Participants Walk Away With
- ✓Implement Autonomous Maintenance Steps 1–3 on production equipment
- ✓Design a planned maintenance schedule using failure mode analysis
- ✓Measure and improve MTBF and MTTR systematically
- ✓Build a TPM implementation roadmap with OEE integration
Programme Modules
Module 1: TPM Philosophy
- From breakdown maintenance to zero breakdown
- 8 Pillars of TPM — overview and interdependencies
- The operator-maintenance partnership model
- TPM maturity levels: where does your factory sit?
Module 2: Autonomous Maintenance (Jishu Hozen)
- The 7 steps of autonomous maintenance
- Step 1: Initial cleaning as inspection
- Step 2: Countermeasures for contamination and hard-to-clean areas
- Step 3: Cleaning and inspection standards
- Steps 4–7: Self-managing equipment (overview)
Module 3: Planned Maintenance Pillar
- Failure mode analysis for equipment
- PM schedule design: time-based vs condition-based
- MTBF and MTTR tracking and improvement
- Spare parts management basics
Module 4: Early Equipment Management
- Machine acceptance standards
- Vertical start-up methodology
- Equipment design feedback loop
Module 5: Quality Maintenance
- Zero defect through equipment condition control
- Linking equipment parameters to quality outcomes
- Inspection standards for quality-critical machines
Module 6: TPM Implementation Planning
- AM Step 1 implementation on selected machines
- TPM pilot area selection criteria
- 6–12 month TPM roadmap for your factory
- KPI framework: OEE, MTBF, MTTR, autonomous maintenance rate
Previously Delivered At
- Plexus Manufacturing (2024–2025)
- TERAJU Pritech 4.0 factories
- Koito Manufacturing (2024)
- Automotive Tier-1 supplier (Selangor, 2023)
Husni Halim
16+ years on the factory floor across semiconductors, aerospace, automotive, oil & gas, and FMCG. Not a classroom-only trainer — a practitioner who ran Kaizen events at Prysmian global plants, delivered projects across 11 countries and 21 international factories, and delivered OEE programmes across 30 Malaysian factories under TERAJU Pritech 4.0 as Lead Consultant. Principal Consultant at Visi Armada Consulting.
HRDC Accredited Trainer
Accredited by Human Resource Development Corporation (HRD Corp) Malaysia
MPC QE5.0 Certified Auditor
Malaysia Productivity Corporation — Quality Excellence 5.0
Certified Process Kaizen Engineer
Efeso Consulting — Milan, Italy
B.Sc. Aerospace Engineering
University of Arizona, USA — 2003
Before You Book
No. TPM is especially valuable for SMEs where production staff must also manage basic equipment care. The autonomous maintenance pillar is designed for exactly this situation.
OEE measures the outcome of your equipment management — TPM is the system that improves it. Availability (the A in OEE) is directly improved by autonomous and planned maintenance. Many clients pair a 2-day OEE programme with a 2-day TPM programme.
TPM reduces downtime by making basic equipment condition visible, giving operators ownership of cleaning and inspection, strengthening planned maintenance, and using OEE, MTBF and MTTR data to attack recurring losses.
The methodology applies to all manufacturing equipment: CNC, injection moulding, SMT lines, conveyor systems, welding stations, and more. The hands-on exercises use equipment from your own factory.
Yes. TPM builds on your existing PM system — it doesn't replace it. The training covers how to integrate AM and planned maintenance with your current CMMS or PM schedule.
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Ready to Book?
Tell us your team size, dates, and which programme you need. We'll send a tailored proposal with full HRDC documentation support within 48 hours.