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TPM / Total Process Reliability Services

Marshall Institute offers expertise in a broad range of TPM/TPR Services from readiness assessments, implementation support and strategic planning, to post implementation audits. Our services assist clients in strengthening their industrial maintenance processes to increase their contribution to the bottom line.

Review the services to determine what you will benefit most from.

Consulting Support

Marshall Institute offers coaching, counseling and advice in the strategic development and tactical implementation of Total Productive Maintenance / Total Process Reliability (TPM / TPR) at your location.

We provide on-going audit assistance. This would involve auditing your TPM / TPR activities on a quarterly or semi-annual basis to help keep your TPM / TPR process "on track." This usually involves two consulting days on-site. At the end of the second day we would provide an oral report outlining the strengths and areas for improvement. A written report is optional.

Our experts have many years of experience in implementing the process at numerous sites, domestically and internationally, and bring a rich background from which to draw. We can share what has worked and what has not to increase the probability of a successful TPM / TPR process at your location.

Pre-Implementation Assessment

Identify how prepared are you for a reliability improvement initiative

Readiness is a key component of Total Productive Maintenance / Total Process Reliability (TPM / TPR) success. To meet the new challenges and changes your organization should have certain basics in place, along with a supportive environment. Through a series of focus groups, one-on-one interviews, observations, and performance analyses, Marshall Institute can provide an in-depth evaluation of your organization's ability to support TPM / TPR.

The pre-implementation assessment identifies:
  • the overall readiness of your operation for implementing TPM / TPR
  • the quality of training processes that will be called upon to support skill development needs of the process
  • the level of senior management support for TPM / TPR
  • the extent of previous training that can be linked to TPM / TPR
  • the quality of communications (interdepartmental and external), since communications are critical to TPM / TPR
  • the quality of the performance management system;
  • examine the overall work climate
  • the quality of the working relationship between production and maintenance
  • the receptivity of TPM / TPR with hourly personnel
  • the strength of the basic maintenance systems
  • areas for improvement regarding maintenance systems
  • potential barriers in implementing TPM / TPR
  • areas of strength that can be further refined
  • specific areas of opportunities for refinement
  • potential next steps
The assessment requires three days on site, and concludes with a feedback presentation of the results. Optionally, it can be followed up with a written report of the findings and recommendations.

Steering Committee Training and Strategic Planning
Establish Long Term TPM/TPR Success with the right leadership

Marshall Institute's TPM / TPR Steering Committee training can help you identify the steering committee structure, the mission, vision, and implementation plan specific to your organization and will provide additional leadership focus to assure success.

The establishment and development of the Steering Committee is vital to the overall success of the Total Productive Maintenance / Total Process Reliability (TPM / TPR) process. The involvement of labor and management employees is critical to designing, integrating and implementing TPM / TPR components into a system that is fair and equitable to employees and the company.

The TPM / TPR Steering Committee, comprised of a cross-section of members’ representative of the functional areas of the plant, and from various levels, will oversee the orderly transition of TPM / TPR processes throughout the plant by identifying and implementing TPM / TPR in pilot areas.

TPM/TPR Overviews
Build the awareness and gain understanding of your TPM/TPR initiative

These short-duration educational sessions create awareness for groups of hourly and salaried personnel.

For your managers, supervisors, and other key personnel, we recommend an eight-hour overview. For others in your operation, a four-hour overview would be adequate for awareness building.

The key point to make to your people is that TPM / TPR is not a maintenance process; it is an operational improvement process. People should understand that TPM / TPR is a shift in the way we do things to improve quality, reduce downtime, and improve throughput. This condensed training will increase the internal support of your TPM/TPR initiative and its chances of long term success.

On-site TPM/TPR Training
Learn to implement TPM processes at your facility

Conducted at your-site, this three-day seminar is designed to train many of your people in the processes of TPM / TPR, as well as how to implement the process.

Based on our TPM/TPR Implementation Model, this progressive course sets forth an implementation strategy for assisting an organization in understanding their current situation, the value of change, developing the required support structure, and strategy for implementing and sustaining reliability improvement.

Basic Equipment Care Workshop
Educate, create and charter cross-functional teams to establish, support and execute effective autonomous maintenance practices

Marshall Institute can assist your operation with the training and implementation of operated-assisted care, commonly known as Autonomous Maintenance, or Basic Equipment Care, and the formation of Equipment Improvement Teams. Equipment Improvement Teams are cross-functional groups made up of operators with maintenance and engineering resource support. They typically meet once a week to work on equipment-related issues.

This hands-on, four-day course explains and demonstrates, through actual in-plant practice sessions, the concepts of Total Productive Maintenance / Total Process Reliability (TPM / TPR);
  • how to function as a team,
  • how to conduct cleaning and inspecting activities
  • how to measure equipment effectiveness
  • how to write standards, and much more.
The training enables team members to begin the process of identifying and resolving equipment-related issues on their equipment. Marshall Institute will assist your organization in training, chartering, and implementing these teams on an on-going, as-needed basis.

Review of Existing Maintenance (PMO/REM)
REM is a PM Optimization technique utilized by a team (Equipment Improvement Teams, usually) to compare the history of failure with the current maintenance strategy (preventive maintenance and predictive practices, if any).

Review of Existing Maintenance is a useful technique because it is almost always the case that current PM programs are ineffective, incomplete, and quite often even wrong, leading to unnecessary and wasteful expenditure of time and money, or the complete lack of appropriate PM activity dealing with known failure modes, producing less than optimum utilization of equipment assets.

The result of successful REM is a more effective maintenance strategy leading to improved performance, less downtime, and lower overall maintenance costs. REM provides the feedback (review and improve) loop missing from most PM programs, thus increasing the value of PM activity, and productive utilization of the asset.

Reliability Improvement Team Training and Charter
Train and charter a team to focus on equipment condition and reliability improvement

This is a 12-week, structured team process that focuses on:
  • the condition of the equipment,
  • the basic care of the equipment (cleaning, lubrication, inspection),
  • and the improvement of the equipment.
RITs will ensure the sustaining of the process (with audits) for the BEC activity. BEC may still be conducted as a stand alone event on less critical equipment.

"Train-The-Trainer" Workshop
TPM / TPR Coordinator Training – Increase their effectiveness to support reliability improvement

Total Productive Maintenance / Total Process Reliability (TPM / TPR) requires constant coaching, reinforcement, following up, coordinating, and training to build a strong process. This requires the dedication of a TPM / TPR Coordinator to facilitate the process at your operation. Marshall Institute offers an extensive, five-day, hands-on workshop designed to provide the necessary skills to help your TPM / TPR Coordinator. Coordinators are trained in the concepts of TPM / TPR,
  • how to facilitate the process
  • how to measure TPM / TPR,
  • how to instruct others in TPM / TPR, and much more.
Attendees learn by doing-40% of the training is working on the equipment, conducting simulated team meetings, or training others. The course comes with a Coordinator's Workshop Manual (which includes lesson plans and transparency masters for presenting TPM / TPR in your facility), a TPM Coordinator's Workshop Learner's Guide, and 3 resource books.

Potential coordinators must have attended a TPM / TPR Implementation program or have general knowledge of TPM / TPR prior to receiving this training.

5S Training
Learn key organizational and orderliness habits to support your TPM/TPR efforts

To support Total Productive Maintenance / Total Process Reliability (TPM / TPR), we offer training and guidance in establishing a 5S program.

5Ss training covers:
  • Organization,
  • Orderliness,
  • cleaning,
  • standardization
  • Self-discipline.
5Ss are often used as a pre-requisite program to TPM / TPR implementation to ensure the organization has developed good habits of organization and orderliness. Also included is our 5S manual, which is great for future reference.

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