PROGRAM'S BACKGROUND

Your customers expect you to provide excellent quality, reliable delivery and competitive pricing. This demands that your machines and manufacturing processes are available when you need them. With a company’s production becoming progressively reliant on the overall effectiveness of fewer but more sophisticated machines and processes, unplanned downtime is no longer affordable. Similarly, these assets are being operated and maintained by fewer and fewer people as the relentless drive for cost reduction continues to bite. This is where the well-proven philosophy and practicalities of TPM (Total Productive Maintenance) come into their own. In this program you will learn how to:

›       Improve your understanding of TPM and how to put it into practice in your company to deliver relevant and sustainable business, equipment and people benefits

›       Adapt (as opposed to simply ‘adopt’, and certainly not ‘corrupt’) the founding principles of TPM according to your company’s business drivers and specific manufacturing processes

›       Design and Implement a relevant framework for TPM champions, drivers and facilitators to work in and to influence the behaviors of multi-disciplinary and multi-interest teams 

PROGRAM'S OBJECTIVES

This Program’s Attendees Will Be More Able To:

›       Examine the history and background to the emergence and relevance of TPM

›       Study how TPM is a key pillar for delivering Lean Thinking and World Class Manufacturing Performance

›       Gain a detailed understanding of how to assess the true Costs and Benefits of TPM in your company

›       Learn the Key and Critical Success Factors for TPM to flourish, including the Soft / Cultural issues

›       Gain a detailed insight into Applying a 9x Step TPM Improvement process, with supporting tools and techniques

›       Learn how to plan and launch your tailored TPM Program from pilots to roll-out

›       Learn how to manage the TPM Journey, including audit, review and benchmarking processes

›       Gain an understanding of applying the TPM philosophy as Total Productive Administration (TPA) in Support functions

›       Explore how TPM is adapted for equipment specifiers, designers and suppliers 

PROGRAM'S ATTENDEES

›       Potential TPM Champions

›       Managing Directors

›       General Managers

›       Probable TPM Driver

›       Middle Managers

›       Supervisors

›       Team Leaders

›       Anyone  representing operations and/or maintenance engineering at the sharp end of the business, responsible for producing quality output from highly reliable and predictable equipment

›       Proposed TPM Facilitator or Coach

›       Potential TPM Practitioner 

PROGRAM'S OUTLINE

PUTTING TPM INTO PERSPECTIVE

›       History and development of TPM

›       Operational excellence, lean thinking and TPM

›       Operational basics and maintenance

›       Where are we now? - self assessment

›       TPM principles and the founding pillars

›       Creating the future vision-the end game

›       Bringing the vision to reality - what is the journey?

›       Some of the soft/cultural issues

TPM TECHNIQUES & PROCESS

›       The 9xStep TPM process and its 3xcycles

›       The Measurement Cycle

›       Equipment history

›       Overall equipment effectiveness

›       A wider perspective off OEE- some myths & realities

›       Six loss assessment

›       The Condition Cycle

›       Criticality assessment

›       Condition appraisal

›       Refurbishment / restoration program

›       Future asset care and autonomous maintenance

THE 9X STEP TPM PROCESS & SUPPORTING TECHNIQUES

›       The Problem Prevention Cycle

›       Developing best practice routines and skills development

›       Problem solving (Asking Why 5xTimes and the ‘100 year Fix’

›       Workplace organization and 5S

›       Standard and safe operating procedures

›       Change-over reduction (SMED)

›       Visual management and fool-proofing

›       Equipment improvement tactics

›       P-M analysis

›       TPM for design

›       TPM in the office/support functions

THE TPM IMPLEMENTATION AND ROLL-OUT PROCESS

›       Planning and Sustaining the TPM Journey

›       Securing management commitment

›       The scoping study-case study

›       OEE and best of best targets

›       Measuring people’s perceptions and feelings

›       Building the cost / benefit case through the loss model

›       Pilot projects and roll-out

›       Improvement zones and milestones

›       Top down and bottom up audit / review processes

DOES TPM PASS THE SO WHAT TEST?

›       Key success factors

›       Main reasons for failure

›       Identifying the risks and the counter-measures to minimize those risks

›       Planning, designing and Implementing your own in-house TPM program 

ADDITIONAL DETAILS