(TPM) Total Productive Maintenance Course

Details of TPM course ...

WHAT IS TPM?

TPM gives Lifetime Equipment Health
• What is Total Productive Maintenance?
• The Hidden Factory
• The Six Production Losses
• The Seven Process Wastes
• Production Losses and Overall Equipment Effectiveness
• The Substance of TPM
• The Never Ending TPM Cycle

EQUIPMENT LIFETIME HEALTH

Total Productive Maintenance is … operator driven reliability:
• Need an Equipment Performance Vision
• Match TPM Process to the Vision
• TPM in a Nutshell

TPM AND ITS OPERATING RISK REDUCTION BENEFITS

Purpose of Total Productive Maintenance
• TPM Works by Reducing Risk of Failures
• Multiple Strategies across the Life Cycle
• Value-Added to Equipment with TPM
• Risk Reduction with TPM

MEASURING EQUIPMENT PERFORMANCE

Monitoring Operating Effectiveness
• Purpose of Measuring Equipment Performance
• Overall Equipment Efficiency (OEE)
• Start Measuring Plant Non-Performance
• Production Disruptions Causes Variation
• Pareto Chart the Problems for Focus

THE IMPORTANCE OF OPERATOR OWNERSHIP OF EQUIPMENT PERFORMANCE

Promoting Operator Ownership
• Operator Monitoring and Watch-keeping
• Equipment Behavior – Identifying the Degradation Cycle
• Operators Learn about their Equipment
• Operator Monitoring & Watch-keeping Procedure
• Fact Based Equipment Decisions

GETTING TOP QUALITY EQUIPMENT PERFORMANCE

Failure Preventing Job Procedures
• Accuracy Controlled Expert
• Accuracy Controlled SOPs Prevent Variation
• Including 3T Failure Prevention in SOPs
• Accuracy Controlled Enterprise (ACE)
• 7 Visual Quality Management Tools for TPM Problem Solving
• Make measurement Visual, … turn numbers into information

REQUIREMENTS FOR SUCCESSFUL TPM INTRODUCTION

Identifying TPM Systems and Processes
• Critical Mass of Support
• The People of Successful TPM
• The Culture of Successful TPM
• Best Performance from Multifunctional Teams
• Role and Importance of Supervisors
• Activity 3 – Building Hi-Performance Teams

TPM REQUIRES CHANGE MANAGEMENT

TPM Requires a Change Management Process for Successful Introduction
• Manage TPM Introduction like a Project
• Providing the whole ‘TPM Mix’
• Sustained Resourcing of TPM Processes
• Prototype a TPM Program for Proof of Worth
• Supporting the TPM program
• Change … Do … Learn … Improve
• TPM Champions Needed

A TPM CASE STUDY

Management Support
• TPM Team Objectives
• TPM Team Development
• Identify Current State
• Prioritize Equipment Problems
• Target Key Problems/Set New Standards
• Authorize Proposed Changes
• Improve Documentation/Training
  - Return Equipment to Condition/Sustain it
• Measure Improvement/Lock-in Gains
• Second and Third TPM Cycles

HOW TO APPROACH PLANNING FOR TPM INTRODUCTIONS

Planning TPM Introduction: using the Change Management Matrix
• TPM Change Management Requirements
• The TPM Route Map
• Develop Detailed Project Plan & Schedule