Total Productive Maintenance (TPM): 2 Days

Total Productive Maintenance (TPM) Training Course Total Productive Maintenance (TPM) Training
By Andrew Cheah
Course Title:
Total Productive Maintenance (TPM)
Training Category:
Manufacturing Operations
Target Audience:
The training is designed for Managers, Engineers from production, Quality & Process Engineering, Technicians, Technical Assistants, Technologists, Executives, Engineering Support Personnel. It is highly recommended for all key staff who are involved in any form of maintenance.
Duration:
2 Days
For In-house Training
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Contact customer service +603-4270-3064
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Delivery Methods
  • Language: English
  • PowerPoint Presentation
  • Group Discussion
  • Presentation Handouts
  • Indoor Activities
  • Participant Presentation
  • Lecture
  • Case Studies
  • Certificate of Participation
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*Terms & Conditions

Course Introduction ›

Maintenance is an integral part of any manufacturing business. With the highly competitive nature of today’s business environment, organizations are required to deliver products to their customers on time, with the lowest cost, and with the highest quality. Without proper maintenance, companies can lose millions of dollars, face unpredictability, and lose confidence in their product quality.

This 2-day workshop aims to provide the participants with the knowledge and tools to improve maintenance performance utilizing Total Productive Maintenance (TPM). The workshop takes participants through tools to help manage the maintenance process and finally apply the right changes at the right time to get optimal results from the process. The topics covered in this workshop are shown below.

After attending the training, participants should be able to identify opportunity available to achieve a 85% and above equipment efficiency (OEE), the defect rate being reduced to a possible zero and obtain a quality yield of 99.99%. Their skill to handle problems and obstacles would be enhanced with proven training techniques.

Course Objectives ›

  • To understand about objectives, concepts & strategy in TPM
  • Understand & describe the 6 major losses in equipment effectiveness.
  • Categorize maintenance in the 5 Total Productive Maintenance (TPM) "pillars"
  • Measure Overall Equipment Effectiveness (OEE) on each piece of equipment in their Value Stream.
  • Improve Overall Equipment Effectiveness (OEE) via application of Total Productive Maintenance's (TPM) 5 Pillars
  • Know the differences between Reactive, Preventive, Predictive & Proactive Maintenance.
  • Accomplish Actual TPM Implementation with Measurable Results
  • Learn about the new approach to equipment management
  • Improve the quality of the workplace environment
  • Evaluate effective ways to eliminate wastages & losses
  • Monitor the situation through reports, audits & activity boards
  • Understand about autonomous maintenance
  • Master the strategies to successfully implementing TPM

Course Outline ›

DAY 1

INTRODUCTION TO MAINTENANCE

  • History & Evolution of Maintenance
  • The importance of maintenance in an organization
  • The "backstage" analogy
  • Knowing your customer

DIFFERENT CONCEPTS OF MAINTENANCE

  • Fail & Fix
  • Scheduled Maintenance
  • Preventive Maintenance
  • Predictive Maintenance

USING LEAN & 5S IN MAINTENANCE

TPM OVERVIEW & OBJECTIVE

  • What is TPM? 5-Point Definition of TPM
  • Activities before TPM
  • Application of preventive & predictive maintenance in TPM
  • Maintenance inventory controls
  • TPM strategy
  • New approach to equipment management

CHARACTERISTICS & GOALS OF TPM

  • 3-Principles of Prevention
  • Improving the quality of the workplace environment
  • Changing our attitudes
  • Changing the equipment
  • Changing the workplace

COLLECTING DATA

  • The importance of data collection
  • Methods of collecting data
  • Different types of data
  • Advanced Measurement Systems Analysis
  • Using Data to find an optimal maintenance strategy
  • Calculating mean time to failure
  • Measuring maintenance performance / metrics

DATA ANALYSIS

  • Why analyze?
  • Important Tools for Data Analysis
    • Pareto Analysis
    • Plots and Graphs
    • Regression
    • Control Charts
DAY 2

ELIMINATING EQUIPMENT LOSSES

  • Breakdown losses
  • Setup & adjustment losses
  • Idling & minor stoppage losses
  • Speed losses
  • Quality defects & rework losses
  • Start-up & yield losses

AUTONOMOUS MAINTENANCE (AM)

  • Benefits of Autonomous Maintenance
  • How to implement AM in your operations
  • Autonomous Maintenance steps
  • Key points to successful AM implementation

CHARACTERISTICS OF AUTONOMOUS MAINTENANCE

  • Organization Led Activities
  • Use of audits
  • Use of activity boards
  • Meetings & reports

PLANNING & SCHEDULING MAINTENANCE

  • The 6 maintenance planning principles

SCHEDULING MAINTENANCE TASKS

SPARE PARTS INVENTORY MANAGEMENT

  • Cost benefit analysis
  • Using Kanban & replenishment models
  • Differences between spare parts inventory & operating inventory

STANDARDIZATION

8 PILLARS OF TPM & 8 STEPS OF AM

  • Autonomous maintenance
  • Individual improvement
  • Planned maintenance & initial control
  • Training & education
  • Office TPM & quality maintenance
  • Safety & environment

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