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INTRODUCTION

Total Productive Maintenance (TPM) is a manufacturing led initiative that emphasizes the importance of people, a "can do" and “continuous improvement" philosophy and the importance of production and maintenance staff working together.  This is the only secret recipe available to the world to achieve zero breakdowns of equipment; zero defects produced by the machine and increase the life cycle of the equipment. 

Thus TPM is concerned with the fundamental rethink of business processes that achieve improvements in cost, quality and speed.  TPM is also crucial in Lean Manufacturing and Six Sigma efforts and eventually to achieve World Class Manufacturing status at OEE 85%.

BENEFITS

·        Prevent breakdowns of equipment

·        Eliminate minor stoppages

·        Minimize production defects

·        Reduce maintenance costs

·        Reduce set-up and adjustment losses

·        Maximum line speed

·        Decrease start-up losses.

TARGET AUDIENCE

·        Production, Maintenance and Engineering Personnel who must work together to achieve their goals.

·        Participation from other areas, e.g. Finance and Administration is also recommended because TPM is based on the power of cooperation.

METHODOLOGY

• Seminars, group exercise and practical on production.

COURSE CONTENTS

DAY 1

1.      Introduction – The Power of TPM

2.      Equipment Condition Analysis

3.   TPM Defined

(a)    History of TPM

(b)   Preventive Maintenance and TPM

(c)    TPM and Product Quality 

4.   The Eight Pillars of TPM – Practice 5 pillars in the production floor

5.   Pillar 1 – 5S Housekeeping

6.   Pillar 2 – Quality Maintenance (QM)

·        Major causes of breakdown and defects

◊ Sporadic defects

◊ Chronic defects

·        Principles of Quality Maintenance

 DAY 2

1. Pillar 3 – Six Big losses to improve equipment efficiency (data collection on production line).

(i)                  Breakdown losses

(ii)                Set up and adjustment losses

(iii)               Idling and minor stoppage losses

(iv)              Reduced speed losses

(v)                Quality defects and rework

(vi)              Start-up / yield losses

2. Think Systematically

• Why-why analysis
• 4Ms method

3. Pillar 4 – Kaizen

4. Where to start TPM

    5.   Measuring Equipment Effectiveness (OEE calculations) – Practical on the Production.

 DAY 3

1. Pillar 5 – Autonomous Maintenance Program (AMP) – Practical on the Production.
   • A 7-step program

(i)                  Initial cleaning

(ii)                Eliminate sources of contamination

(iii)               Standards for cleaning and lubrication

(iv)              General inspection

(v)                Autonomous inspection

(vi)              Organize and manage workplace

(vii)             Advance improvement activities

2. Pillar 6 – Training Operators to understand their equipment – Practical on the Production.

·        The 4 skills for AMP

(i)                  Ability to detect equipment abnormalities

(ii)                Ability to understand equipment functions

(iii)               Ability to understand relationship between equipment and quality.

(iv)              Ability to make repairs

3. Pillar 7 – Planned Maintenance (Practical)

·        6 steps in planned maintenance

·        Key TPM strategies for maintenance department

4. Pillar 8 – Safety, Health & Environment