Reference Materials for Dojo Basic Maintenance Skills Training

In my previous post, I highlighted the importance of a training center or “Dojo” for operators. This training is crucial for autonomous maintenance tasks for TPM, covering fundamental machine skills and equipment care. This update post features reference manuals that can aid in creating and delivering this training. Key components of the training should include:

• Basics of autonomous maintenance and the tagging systems In reference to your specific equipment

• Fasteners, Lubrication, and Seals

• Mechanical assembly and power transfer

• Basics of electricity and electrical safety

• Electrical control circuitry

• Basics of hydraulics and pneumatics

• Basics of pumps and piping

  
  

The training activities and training room should be tailored to your equipment and delivered by members of your maintenance staff, who are experts on your existing equipment. When we began pursuing the JIPM TPM Excellence Award, we formed a team of our best maintenance personnel from 5 of our key manufacturing locations and provided a “Train the Trainer” course to help the trainers develop the training plan, including the design of the training room and the equipment needed.

Manuals used for training

Mondzukuri Test Learning Textbook – “Chapter 5 Basics of Routine Maintenance”

As a starting point, you might need a high-level guide to the concepts of this type of training. In that case, Chapter 5 of the JIPM reference manual, “Monodzukuri Test Learning Textbook,” provides an excellent example of the type of material needed for basic maintenance skills. At this time, the Monodzukuri book can only be obtained from the Japan Institute of Plant Maintenance

The actual Monodzukuri textbook is over 300 pages, and the last 100 pages are dedicated to Chapter 5, “Basics of Routine Maintenance.” Chapter 5 is an excellent outline of the key items needed for the Operator Basic Maintenance Skills training.

Reference manuals for the students

The following are popular reference manuals that cover major topics appropriate for the Dojo training and can all be obtained from Amazon:

• “Industrial Mechanics and Maintenance” -- Chastain

• “Mechanical Trades Pocket Manual” -- Davis, Nelson

• “Hydraulic and Pneumatics” – Parr

• “Electrical Course for Apprentices & Journeymen” -- Rosenburg

By referencing these manuals during training, it underscores the importance of delivering each key learning point with additional supporting text and drawings, as needed.

 Industrial Mechanics and Maintenance, Chastain

This modern book presents a solid foundation in basic theory and a practical "hands-on" approach, including exposure to real-life equipment in today's industry.  The manual integrates safety and troubleshooting components within each chapter to encourage diagnostic skill-building.

 Mechanical Trades Pocket Manual, 4th Edition, Davis, Nelson

This convenient guide covers the latest industrial equipment and all the tools and machines prevalent in older plants, even those from the early 1970s and before.

 Hydraulics and Pneumatics, Parr

Hydraulics and Pneumatics: A Technician's and Engineer's Guide guides the hydraulic and pneumatic systems operations.  The Manual features mathematical content presented in a style understandable even to beginners and non-experts.

 Electrical Course for Apprentices & Journeymen, Rosenberg

The manual contains everything you need to know about electrical theory and applications, clearly defined and logically organized, with illustrations for clarity and review questions at the end of each chapter to help you test your knowledge.