Modern Total Productive Maintenance (TPM)
Dr. Gene A Constant · 2026 revised edition · the whole book, free to read here
- The six big losses.
- The eight pillars.
- The road to TPM 4.0.
Why machines never behave like the plan, and how a plant designs loss out instead of fighting fires. Twenty chapters: the losses and the pillars, quality, early equipment management, people and safety, the office, then data, sensors, predictive maintenance, OEE, sustainability and a roadmap to TPM 4.0. Read it here, or listen while you walk the floor.
Safety first, every time. Reading this book does not qualify anyone to work on live equipment. Any task that needs lockout, energy isolation, disassembly or specialised measurement belongs to trained maintenance staff following your site's own procedures.
The free class: twenty lessons
One lesson per chapter, in the book's order. Each one breaks the chapter into its ideas, gives you something to work, and asks new questions every attempt. All twenty are open. Free, no account, and your progress stays on your own device.
- 1The foundations of modern TPMWhere TPM came from, the full spectrum of loss, eyes for abnormalities, and restore, stabilize, then improve.Open
- 2The six big lossesBreakdowns, setups, minor stops, speed, defects and startup, one loss at a time.Open
- 3The eight pillarsAutonomous maintenance, planned maintenance and focused improvement: the three pillars the chapter teaches in depth.Open
- 4Quality maintenance and defect preventionKeeping defects from returning by controlling the equipment conditions that create them.Open
- 5Early equipment managementDesigning maintainability in, so a new machine does not fight the plant for years.Open
- 6Training, education and empowermentBuilding the capability that makes TPM stick after the launch.Open
- 7Safety, health and environmentSHE as part of equipment care, not a parallel programme.Open
- 8TPM in administration and supportWhen the line is ready but the system is not: parts, work orders and paperwork as losses.Open
- 9The role of dataTurning signals into consistent action: stop, slow, or continue with safeguards.Open
- 10IoT, sensors and predictive maintenanceCondition monitoring and prediction, starting where the data chapter ends.Open
- 11Autonomous maintenance in the digital eraKeeping daily care and digital intelligence in one system, not two.Open
- 12Planned maintenance and predictionRestoring deterioration before it collects its debt.Open
- 13Focused improvement and data-driven kaizenAttacking the chronic losses that predictive maintenance exposes.Open
- 14Quality through computer vision and AIClosed-loop quality at the last meter of the line.Open
- 15Virtual prototypingEarly equipment management with virtual prototypes, so a design is proven before it is built.Open
- 16The human factor in Industry 4.0Capability under pressure, across shifts, with psychological safety and discipline.Open
- 17AI, 5G and blockchainThe technology backbone of a factory operating system, including agentic AI.Open
- 18Measuring success: OEE and KPIsA small set of metrics the plant trusts, and the arithmetic behind them.Open
- 19Sustainability and green manufacturingCarbon treated as another form of loss, not only a reporting obligation.Open
- 20The roadmap to TPM 4.0Phase by phase: make the factory safe to improve, then scale without copying.Open
The Certificate of Comprehension
Forty questions drawn from all twenty lessons, graded on our server; you need 80% to pass. A pass prints a serial-numbered certificate with a link anyone can use to verify it. It records comprehension of the book. It is not a licence or an industry credential.
Sit the exam Open the class page