Achieving Total Process Reliability through TPM

Customers want your product NOW! Can you deliver it, or will they get it from your competitor?

This course is offered by request for live-remote, or on-site training at your facility.

The reliability of your equipment is crucial to the success of your organization. When your equipment is functioning properly, you can effectively deliver your product. However, if your equipment breaks down, your business suffers. Total Productive Maintenance (TPM) is a proven strategy that can enhance the reliability, productivity, and output of your equipment while minimizing unscheduled downtime and operating costs. These improvements directly impact your bottom line, making TPM an essential aspect of your business.

To help you successfully implement TPM, we have developed a comprehensive training program. Our seminar is based on Marshall Institute’s acclaimed 8-Phase TPM Implementation Model, which provides step-by-step guidance for integrating TPM into your company. During the training, you will learn which Key Performance Indicators to focus on to accurately measure the success of your TPM efforts. Additionally, we will provide you with an OEE calculator and hands-on coaching to help you assess the reliability of specific equipment or production lines.

Our seminar also emphasizes the importance of gaining momentum and securing buy-in and support during the initial stages of TPM implementation. We will equip you with tools such as Basic Equipment Care, 5S for Maintenance, and Root Cause Analysis, which will enable you to achieve quick wins and generate enthusiasm among your team.

By attending this seminar, you will gain the knowledge and skills necessary to drive successful TPM implementation in your organization. You will be equipped with valuable guidance and tools that will enable you to increase equipment reliability, productivity, and output while reducing unscheduled downtime and operating costs. Don’t miss out on the opportunity to achieve real, bottom-line improvements for your business. Register for our TPM training seminar today.

On-site Delivery Only

This seminar is currently offered as an On-site event, delivered at your facility.

To learn more about how we can train you and your team, please complete the request On-site Training form. We will contact you to discuss training details, logistics, schedule availability and pricing.

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Agenda

Day 1

Welcome and Orientation

Basic Concepts of TPM/TPR

- What is TPM/TPR?
- Principles of TPM/TPR
- Benefits of TPM/TPR
- The TPM/TPR Process

Basic Equipment Care—operator involvement in routine equipment care

- What is BEC?
- Why BEC?
- 7 Steps of BEC
- Implementing BEC

**Maintenance Excellence—improving maintenance systems (Part 1)**

- What is Maintenance Excellence?
  - Managing Work Flow
    - Key Maintenance Activities
      - CMMS
      - Work Identification and Prioritization
      - Plan

Day 2

**Maintenance Excellence—improving maintenance systems (Part 2)**

- - Managing Work Flow (cont’d)
    - Key Maintenance Activities (cont’d)
    - Schedule
    - Execute
    - Closeout
    - Analyze
  - Key Maintenance Activities Roles & Responsibilities
  - 5S Application to Maintenance

Knowledge & Skills—improving skills

Elements of an Effective Training Program
- Required Skill Level
- Status Current Level of Skills
- Develop a Plan to Close the Gap
- Delivery Tools and Techniques
- Deliver Training and Assess

Equipment Improvement— focused improvement

Team Concepts
Equipment Improvement Tools
- Equipment Improvement Teams (EIT)
- Overall Equipment Effectiveness (OEE)
- Root Cause Analysis (RCA)
- Single-Minute Exchange of Die (SMED)—aka “Quick Change”
- Mistake Proofing

Equipment Design Excellence—early involvement of all stakeholders in equipment acquisition

Key Principles
Equipment Design Excellence Process Design Steps

Day 3

Change Management

What is Change Management?
Five Principles of Change Management
1. The Driving Force for Change
2. Leadership Coalition
3. Employee Engagement
4. Quick Wins/System Improvements
5. Sustain the Change

Implementation Strategy

Implementation—Reliability Improvement Model
Next Steps

Review/Questions

Wrap-up /Adjourn

Who should attend this seminar?

5VP Operations
5VP Production
5VP Engineering
5Maintenance Directors
5Manufacturing/Production Managers
5Maintenance Superintendents
5Maintenance Personnel
5Production Managers
5Continuous improvement Managers
5Reliability Managers
5Maintenance Supervisors
5Reliability Engineers
5Plant Industrial Engineers
5Operations Managers
5TPM/TPR Coordinators

You will learn to…

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Basic Equipment Care

We will show you how Operator Involvement and Skill Development play important roles in improving equipment reliability. Spotting and responding to deterioration in equipment infancy can prevent breakdowns. 65-75% of all breakdowns can be prevented by having the operator closest to the equipment clean, lubricate, and inspect on a regularly planned basis

R

Equipment Improvement Teams

Learn how Equipment Improvement Teams (small group activities) with cross-functional membership can be applied in identifying and resolving equipment problems. We’ll show you how to apply these time-tested principles that will move you from reactive to proactive through employee commitment.

Attend this seminar if you want to:

PUnderstand the principles of maintaining basic equipment conditions through the 7 steps of Basic Equipment Care
PDescribe and understand the tools utilized to eliminate chronic problems
PIdentify the right resources and principles needed to ensure improved engineering and design of new equipment
PUnderstand the principles of change management and apply the individual roles of leadership in change management as it relates to TPM/TPR implementation
PDemonstrate the ability to create a short term initial action plan
PMuch more...

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Alan Warmack

Director of Training Services