6 - 9 April 2026 DUBAI, UAE

Join Us In-Person or Online

4 Days Next-Gen Total Productive Maintenance (TPM) Masterclass : Intelligent Asset Performance

Modern Technologies, AI Interface & Predictive Analytics for Maximum Uptime & Cost Efficiency

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Master Trainer

John Hay

International Consultant, Trainer & Maintenance Strategist — United Kingdom

John Hay is an internationally recognised maintenance strategist, author, and trainer with more than 30 years of hands-on and consulting experience across manufacturing, oil & gas, utilities, and heavy industries. He has helped organisations across Europe, the Middle East, and Asia establish world-class maintenance and reliability frameworks that reduce downtime, strengthen workforce capability. 

John has trained and advised maintenance and reliability teams across the world, with clients including: Shell Global • Saudi Aramco • TotalEnergies • ADNOC (Abu Dhabi National Oil Company) • SABIC (Saudi Basic Industries Corporation) • Marathon Oil • Chevron • DONG Energy • Petroleum Development Oman (PDO) • DEWA (Dubai Electricity & Water Authority)

Key Achievements

  • Led TPM and Reliability Excellence initiatives achieving measurable reductions in maintenance costs and unplanned downtime across major industrial facilities.
  • Designed and delivered advanced TPM capability programmes integrating maintenance, production, and engineering functions to build a unified reliability culture.
  • Supported asset-intensive organisations in benchmarking, gap analysis, and OEE improvement strategies aligned with international performance standards.
  • Delivered consulting and training engagements for over 100 plants globally, focusing on practical implementation and workforce alignment

Awards & Recognition

  • Recognised thought leader in Total Productive Maintenance (TPM) and Cost Optimisation methodologies.
  • Known for translating technical TPM concepts into step-by-step frameworks that yield quantifiable results.
  • Invited speaker and workshop leader at global maintenance and reliability summits.

What Clients Say About John Hay

“John’s approach combines theory with deep practical insight — his workshops deliver real-world improvements we could measure within weeks.” — Maintenance Excellence Manager, Oil & Gas Sector

“A rare balance of technical mastery and people engagement — our maintenance team came out motivated and aligned.” — Reliability Director, Industries Group

“John bridges the technical with the cultural. His sessions built a sense of ownership in our operators and engineers that no other programme had achieved.” — Operations Excellence Leader, Global Cement Producer

“Brilliant delivery — data-driven yet easy to follow. Our reliability metrics are stronger, and the team now speaks a common TPM language.” — Head of Maintenance & Reliability, Petrochemical Company

Next-Generation Total Productive Maintenance (TPM) Masterclass 2026

Why You Can’t Miss This Masterclass?

Industries competitiveness now depends on how effectively organisations manage the reliability, cost, and productivity of their assets. Many TPM initiatives fail not because of lack of intent, but because teams struggle to sustain momentum, measure impact, and align maintenance with business performance.

This masterclass provides a structured path to rebuild TPM from the ground up — integrating proven practices with data, AI, and human engagement to deliver visible, measurable results.

Over four intensive days, delegates will:

  • Translate TPM principles into actions that reduce downtime and maintenance cost.
  • Master calculations for TEEP and equipment efficiency to quantify improvement.
  • Strengthen workforce ownership and cross-functional collaboration.
  • Learn how to sustain TPM beyond initial rollout through culture and governance.

Course Overview

In today’s manufacturing industry landscape, companies are under constant pressure to increase productivity, reduce downtime, and improve equipment reliability — all while maintaining workforce engagement and safety standards.

The Next-Generation Total Productive Maintenance (TPM) Masterclass 2026 equips plant and maintenance leaders with practical methods to strengthen asset performance through teamwork, ownership, and data-driven maintenance. Built on the foundational principles of TPM, this course extends them into the digital era — integrating Artificial Intelligence (AI) to enhance predictive accuracy, automate insights, and optimise resource utilisation. Together, AI and TPM create a powerful synergy that connects human expertise with intelligent analytics, driving smarter, safer, and more reliable operations.

Delegates will learn how to apply TPM pillars to their own environment, perform key calculations such as TEEP, and translate results into measurable gains in reliability, safety, and cost efficiency. The focus is not only on how to start TPM — but how to sustain it and embed continuous improvement into the culture of the plant.

This Masterclass is Ideal For

Professionals responsible for driving reliability, performance, and cost efficiency in plant operations and maintenance environments, including:

  • Plant Managers and Operations Directors
  • Maintenance and Engineering Managers
  • Reliability and Asset Performance Leaders
  • Production and Industries Heads
  • Continuous Improvement and Operational Excellence Managers
  • TPM / Lean / Kaizen Practitioners
  • Maintenance Planning and Scheduling Engineers
  • Technical and Maintenance Supervisors
  • Health, Safety & Environment (HSE) Managers
  • Industrial Performance and Cost Optimisation Professionals

Learning Outcome

  • By the end of this masterclass, participants will be able to:
  • Apply TPM pillars to reduce unplanned downtime, improve reliability, and sustain performance gains.
  • Measure and interpret TEEP and other key indicators to track efficiency and equipment health.
  • Integrate AI-driven insights and data analytics into maintenance decision-making and resource planning.
  • Strengthen maintenance planning, scheduling, and spare-part control to achieve cost reduction targets.
  • Build a culture of ownership and continuous improvement across maintenance and operations teams.

Key Objectives

This masterclass is designed to help participants strengthen maintenance efficiency, reliability, and cost control through practical TPM implementation and data-driven improvement.

By the end of the programme, delegates will be able to:

  • Apply TPM principles to minimise unplanned downtime and improve equipment availability.
  • Measure and improve TEEP and related KPIs for better asset performance tracking.
  • Integrate data analytics and AI insights into maintenance planning and reliability improvement.
  • Develop cost-reduction strategies by identifying waste, optimising spare parts, and enhancing workforce utilisation.
  • Build a sustainable TPM culture that drives ownership, safety, and continuous improvement.

Course Outline

Day 1 – Building the Foundation for Total Productive Maintenance

Day 2 — Predictive Maintenance and Digital Reliability

Day 3 — Critical Equipment, Safety & Digital Assurance

Day 4 — Cost Reduction and Maintenance Optimisation

Theme: Establishing TPM philosophy, structure, and leadership alignment to drive reliability, performance, and workforce engagement across production systems.

Module 1 — Introduction to TPM and Its Strategic Role
Module 2 — Launching a TPM Programme for Sustainable Performance
Module 3 — TPM Pillars and Real-World Applications

Day 1 provides the foundation for TPM mastery. Delegates leave with a clear understanding of how TPM principles and AI-assisted practices converge to drive measurable reliability, safety, and operational excellence across GCC industrial settings.

Theme: Transforming data into foresight. Day 2 focuses on integrating predictive maintenance (PdM 4.0), reliability-centred frameworks, and AI-driven analytics to prevent unplanned downtime and sustain world-class reliability.

Module 4 — Starting a TPM Programme: The Improvement Toolbox
Module 5 — Reliability-Centred Maintenance (RCM 4.0)
Module 6 — Predictive Technologies and AI Optimisation

Delegates will leave Day 2 with a complete framework for reliability transformation—blending TPM, RCM, and AI to create proactive maintenance ecosystems that enhance safety, profitability, and asset longevity.

Theme: Strengthening maintenance integrity and operational safety through structured risk-based methods, criticality ranking, and technology-enabled control systems. Delegates learn how to safeguard high-risk assets, manage Safety Critical Elements (SCE), and digitalise oversight using CMMS and KPI frameworks.

Module 7 — Criticality Analysis and Risk-Based Maintenance
Module 8 — Managing Safety Critical Elements (SCEs)
Module 9 — Computerised Maintenance Management Systems (CMMS)

Day 3 solidifies the bridge between human reliability and system intelligence. Delegates gain a clear roadmap for critical asset management, risk-based decision-making, and digital integration—ensuring safety, uptime, and compliance at scale.

Translating reliability excellence into measurable financial outcomes. Day 4 focuses on maintenance cost structures, waste elimination, and value-based decision frameworks that link technical improvements directly to profitability.

Module 10 — Maintenance Cost Drivers and Benchmarking
Module 11 — Optimising Preventive & Predictive Maintenance
Module 12 — Sustaining Cost Efficiency through Continuous Improvement

Day 4 equips delegates with structured frameworks and financial-alignment tools to turn maintenance excellence into bottom-line impact. Participants leave with ready-to-use templates for cost tracking, benchmarking, and sustainable optimisation.

All delegates required to bring laptops for follow along practical sessions

Masterclass
Methodology

This masterclass is designed to be practical, learner-friendly, and hands-on, ensuring participants not only understand TPM concepts but can immediately apply them to real maintenance challenges. Every module combines theory with practice through interactive exercises, simulations, and guided implementation steps.

Learning is built on the principle: “If I listen, I forget. If I see, I remember. If I do, I understand. If I teach, I learn.”

The methodology includes:

  • Pre-course questionnaire to align the content with each participant’s plant priorities
  • Instructor-led presentations linking TPM principles with measurable business outcomes
  • Real-world case studies, audio-visual examples, and technical process learning
  • Interactive games, calculations, and group exercises that reinforce core concepts
  • Peer discussions to help sustain TPM, foster teamwork, and embed continuous improvement
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