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Total Productive Maintenance

Total Productive Maintenance is a world-class approach to equipment management that involves everyone, working to increase equipment effectiveness. The TPM approach allows you to deploy a comprehensive set of tools and techniques to eliminate all losses across a whole organisation and throughout the value stream.

Description

Introduction
Total Productive Maintenance is a world-class approach to equipment management that involves everyone, working to increase equipment effectiveness. The TPM approach allows you to deploy a comprehensive set of tools and techniques to eliminate all losses across a whole organisation and throughout the value stream.
 
TPM involves the capabilities of the whole workforce to ensure effective and sustainable improvements are implemented. Improvements to the organisation are made by improving the two core elements of people and equipment.
 
TPM brings maintenance into focus as a necessary and vitally important part of the business. It is no longer regarded as a non-profit activity. Down time for maintenance is scheduled as a part of the manufacturing day and, in some cases, as an integral part of the manufacturing process. The goal is to hold emergency and unscheduled maintenance to a minimum.
 
Implementing TPM establishes processes and metrics that focus attention on minimizing the non–value-added tasks. The resulting increase in productivity applies not only to the equipment, but to the people working in the manufacturing system as well.
 
TPM Has 3 Basic Goals:
  • Zero Product Defects
  • Zero Equipment Failures
  • Zero Accidents
 
This is achieved by Gap Analysis of previous historical records of Product Defects including customer complaints and Equipment Failures and Accidents. A clear understanding of this Gap Analysis through Cause-Effect Analysis, Why-Why Analysis, and P-M Analysis and other tools are used to plan a physical investigation to discover the weak areas.

Course Objectives

The Objectives Of This Course Are:
  • An understanding of different types of Maintenance
  • An understanding of the techniques to eliminate the 12 wastes.
  • An understanding of the 8 Pillars of TPM their impact on equipment reliability
  • An understanding of the techniques and methods that promote the company-wide support for a successful TPM implementation.
  • Awareness of the value of the TPM implementation process.
  • How to stabilize workstation conditions and significantly reduce equipment and system failures.
  • How to simplify routine maintenance and inspection procedures.
  • Improve effectiveness of preventive maintenance and promote equipment restoration and reliability.
  • How TPM leaders can improve operators' skills in conducting a variety of improvement activities to achieve equipment reliability.
  • Development of TPM Leaders to promote and co-ordinate improvements.
  • Understand how to Implement TPM by following our Step-by-Step Roadmap
  • Recognising and solving the root causes of your equipment failures.
  • Knowing when to use reliability engineering to get the most benefit for your operation.
  • Realising where reliability engineering can deliver simple and low-cost reliability improvements to you.

Who is this Training Course for?

TPM involves everyone in the organization from operators to senior management in equipment improvement. It encompasses all departments and the following departments should attend training:
 
  • Maintenance artisans and managers
  • Operations managers and supervisors
  • Planner & Schedulers
  • Design Engineering
  • Project Engineering
  • Construction Engineering
  • Inventory and Stores
  • Purchasing/Procurement
  • Plant and Site Management
  • Production Supervisors
  • Machine Operators with experience and earmarked to be developed to supervisor

The Course Content

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:
  1. The 12 critical resources required in maintenance
  2. 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

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