Introduction to Total Productive Maintenance (TPM)
This four day long training class provides on-site analysis of your current state maintenance program. Recommendations for improvements to achieve the first steps of a Total Productive Maintenance program (TPM) are presented. Training a selected team on TPM principles is one of the objectives along with implementing TPM processes. The team will leave the session with a detailed understanding of TPM, how to start the process and the benefits. The team will be provided with a customized implementation plan for achieving the first steps of TPM.
Day One and Two
Day one and two will consist of a KAIZEN Institue Lean Advisor and one or two key employees reviewing your facility’s current machine maintenance program. The review will involve all key machines, machine maintenance, downtime analysis, and key metrics.
Day Three and Four
The third and fourth days will consist of a classroom review of the TPM principles, examples of possible improvements, and industry metrics. On the final day, a detailed implementation plan is provided in order for your company to reach the first pillars of TPM. This plan is designed from the data gathered through the reviews of the first two days.
At the completion of the four day event, the company has a path to guide them on the transition from their current state maintenance program to a future state TPM program.
Objectives
Participants will understand the objectives and set-up of the TPM-system (8 TPM columns). They know the TPM main losses and learn the methods of autonomous maintenance. They are able to participate in the introduction of TPM. They know the KAIZEN methods for preempting production disruptions and they understand that sound recording of data is necessary for combating faults (visual management).
Course Outline
- Introduction TPM
- Kobetsu KAIZEN process
- Systematic reduction of the 16 main losses
- Recording of the key figures of production (OEE)
- Target-oriented qualification of staff
- Autonomous maintenance
- Scheduled maintenance
- Recording of the key figures of maintenance (MTBF/MTTR)
- Measures for the optimization of maintenance efficiency
Who Should Attend
Everyone who is responsible for the implementation and performance of TPM measures. Production, maintenance, planning, technical services staff as well as people engaged in the improvement process.
*TPM is a registered trademark of JIPM (Japan Institute of Plant Maintenance)
Objectives
During the seminar, participants will gain a detailed insight into the entire build-up of the TPM Management system and will be able to contribute to the introduction of TPM. They will learn the TPM tools for the recording, prevention or reduction of losses in the process sequences. They will be able to work for operators to create training modules.
Course Outline:
Kobetsu KAIZEN
- 12-step program, developing a loss structure, practical exercise
Autonomous maintenance – stage 4 and stage 5, as well as prospects for stages 6 and 7
- Distributing assignments for Operator / Maintenance operatives
- Build-up of training modules
- Training capabilities for independent maintenance
Planned maintenance – Stage program
- Developing an information system
- Developing a maintenance strategy, determining maintenance priorities
- Methodical recognition and elimination of weak points
Start-up monitoring
- Developing TPM-conforming machines and facilities
- Presenting a MP system
Who Should Attend
Everyone who is mandated with the implementation of a TPM Management System. All Production, Maintenance, Planning, Quality Management, Technical Services, Education, Training and CIP staff.
*TPM is a registered trademark of JIPM (Japan Institute of Plant Maintenance)