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Afflatus Consulting GroupAfflatus Consulting Group

Course sheet · 2027 catalogueOperational excellence

TPM and Autonomous Maintenance

Two days to engage production and maintenance in TPM and start autonomous maintenance on a piece of equipment at your site. Overall equipment effectiveness is calculated from your own stoppages, the major losses are identified, then a clean-and-inspect session is run on the machine with the operators. You leave with the first autonomous maintenance standards and a plan for the following steps.

Duration2 days

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Objectives

  1. Explain the pillars of TPM and how roles are shared between production and maintenance
  2. Calculate the overall equipment effectiveness (OEE) of a machine and identify its major losses
  3. Run a clean-and-inspect session on a machine and deal with the anomalies found
  4. Write cleaning, inspection and lubrication standards for operators
  5. Plan the roll-out of the autonomous maintenance steps

Programme

Day 1 — morning

  • TPM: aiming for zero breakdowns, zero defects, zero accidents, and its pillars
  • The major equipment losses: breakdowns, changeovers, minor stops, reduced speed, defects, start-up
  • Overall equipment effectiveness: availability, performance, quality
  • Exercise: calculating the OEE from your line's stoppage records

Day 1 — afternoon

  • Autonomous maintenance: the steps, from restoring basic condition to team autonomy
  • Sharing tasks between operators and maintenance technicians
  • Anomaly tags, sources of contamination, hard-to-reach areas
  • Preparing the clean-and-inspect session: safety, lockout, tools, roles

Day 2 — morning

  • Clean-and-inspect of a machine at your site with the line team
  • Spotting and tagging anomalies
  • Immediate treatment of simple anomalies and planning of the others
  • Photos and records for the machine's reference state

Day 2 — afternoon (workshop)

  • Workshop: interim cleaning, inspection and lubrication standards for the equipment
  • Visual management of check points: markers, levels, direction of rotation
  • Follow-up indicators: OEE, anomalies open and closed, breakdowns
  • Roll-out plan for autonomous maintenance
  • Knowledge test on TPM and OEE

Teaching methods

  • OEE calculated from the actual stoppage records of your line
  • Half a day of clean-and-inspect on a machine, in line with the site's lockout rules
  • Pairs of an operator and a maintenance technician
  • Anomaly tags and standard templates provided
  • Discussions in Darija possible on the shop floor with line operators

Assessment and documents

Knowledge test, end-of-course evaluation at D+1, numbered training certificate verifiable online and training report, together with the list of anomalies found and the interim standards for the equipment.

Bilingual materials for every participant; each classroom course comes with its digital twin on OmniLearn.

Frequently asked questions

Does autonomous maintenance shift maintenance to the operators?

No. Operators take over cleaning, inspection, simple lubrication and reporting anomalies. Maintenance keeps the technical interventions and can concentrate on preventive work and equipment improvement.

Which machine should we choose for the workshop?

A machine that matters for production, whose stoppages are known, and that can be stopped and locked out for half a day. We choose it with you according to the production schedule.

Do we need a CMMS?

No. The course works with the records you have, even on paper. If a CMMS exists, its stoppage histories are used to calculate the OEE.

Practical information

Duration
2 days
Audience
Maintenance, production, methods, line leaders and operators
Prerequisites
No prerequisites
Group size
Groups of 6 to 12 participants, in-company
Format
In-company, face to face on your site
Language
French, Darija or English; bilingual materials
Funding
OFPPT special training contracts (TFP), GIAC, Maroc PME: we prepare the applications with you, at no extra cost.
Programme customisation
Programme adapted to your procedures, your equipment and your audience

Organise this course

Price and dates on quote, depending on your headcount, your site and your preferred period.

Request a quoteDownload the PDF sheetCall +212 661 863 618

Going further

Our consultants can also support the project on your site. Organisational Diagnostic and Tech-Enabled Transformation

Related courses

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Train your teams on your own site

Book a call with a consultant or request an in-company session: we adapt the programme to your procedures and your audience.

Or call us on ⁦+212 661 863 618⁩

contact@afflatusconsulting.com