Day 1
Module 1: Maintenance in perspective
- Introduction to Maintenance
- The Objective of Maintenance
- Overview of the 12 Types of Maintenance including:
o Breakdown maintenance
o Preventive maintenance
o Autonomous Maintenance
o Reliability Centered Maintenance
o Planned Maintenance
o Equipment design and predictive maintenance
- Equipment Effectiveness and Availability
- Overall Equipment Effectiveness (OEE)
- Performance/output Efficiency
- Group Discusions:
- The 12 critical resources required in maintenance
- The 12 criterions for teamwork
Module 2: Fundamental Requirements of Effective Maintenance
Discussion of the basic tasks that will result in reliable plant systems, including:
- Human Senses
- Using Sensor Technology
- Careful Inspections
- Establishing Thresholds points
- Machine Lubrication
- Calibration to keep measurement and control instruments within limits
- Lock Out Tag Out Procedures (LOTO)
- Statistical Process Control basics
- · Scope of Responsibility: Primary and Secondary Maintenance roles
Module 3: Introduction to Total Productive Maintenance
- The Definition of Total Productive Maintenance
- The Impact of Total Productive Maintenance
- The History of TPM
- How TPM compliments the Lean Philosophy
- Similarities and differences between TQM and TPM
Day 3
Module 4: Objectives and benefits of TPM
- Objectives of TPM
- Eliminating Process Losses
- Benefits of TPM
- Reduced Variation
- Increased Productivity
- Reduced Maintenance Costs
- Reduced Inventory
- Improved Safety
- Improved Morale
Module 5: The 8 Pillars of TPM
5S: A foundation for well-running equipment
Pillar 1: Achieve autonomous maintenance (Jishu Hozen)
Pillar 2: Focussed Improvement (Kobetsu Kaizen)
Pillar 3: Planned Maintenance
Pillar 4: Training and Education
Pillar 5: Early Management
Pillar 6: Quality Maintenance
Pillar 7: Office TPM
Pillar 8: Safety, Health and Environment
Module 6: Measuring TPM Effectiveness
- TPM Metrics
- Overall Equipment Effectiveness (OEE) and the 6 big losses
- TPM Activities
- TPM Problem Solving by using the 7 quality control tools
Day 4
Module 7: Implementing an effective Lubrication Program
- Overview of Plant Lubrication
- Lubrication: Duties and Responsibilities of Management and Employees
- The activities to achieve and carry out an effective lubrication program
- Establishment of Lubrication Schedules and Improvements in selection and application of Lubricants
Module 8: TPM Implementation Guidelines
Step 1: Announcement of TPM
Step 2: Launch a formal education program
Step 3: Create an organizational support structure
Step 4: Establish basic TPM policies & quantifiable goals
Step 5: Outline a detailed master deployment plan
Step 6: TPM kick-off
Step 7: Improve the effectiveness of each piece of equipment
Step 8 : Develop an autonomous maintenance program for operators
Step 9: Develop a planned or preventive maintenance program
Step 10: Conduct training to improve operation and maintenance skills
Step 11: Develop an early equipment management program
Step 12: Continuous improvement
Module 9: TPM Success Factors and Enablers
- Management Support
- Focused Approach
- Operator Ownership
- Just-In-Time Training
- Integrated Processes and Schedules
- Overcoming the barriers to effective TPM Implementation
- Final Recommendations for Improvement