TOTAL PRODUCTIVE MAINTENANCE (TPM)

workshop

Building the foundation for manufacturing excellence.

Description

Total Productive Maintenance (TPM), as a Lean Manufacturing methodology, is a company-wide initiative for maximizing the effectiveness of equipment.

 

The goal of the TPM program is to significantly increase labor and capital productivity while, at the same time, increasing employee morale and job satisfaction.

 

TPM brings equipment management into focus as a necessary and vitally important part of the business. Targeted at all levels of the organization, TPM and its eight pillars provide the necessary process and tools to achieve zero defects, zero breakdowns and zero accidents. 

In this two-day workshop facilitated by our JIPM-certified TPM consultant, you will learn the TPM management philosophy as a foundation for Lean transformation, the eight pillars of TPM activities, how to set up a TPM implemenation organization and the step-by-step TPM implementation approach.

 

In addition, you will also learn the essential tools for TPM team activities such as activity boards and one-point lessons, and recognize the six big equipment losses so as to improve Overall Equipment Effectiveness (OEE).

Recommended Audience

This course is recommended for Managers, Engineers, Supervisors, TPM steering committee and other operational staff from production, manufacturing, engineering and maintenance.

Methodology

  • Facilitated by JIPM-certified TPM Instructor

  • Lectures, video presentations, group activities and discussions and Q&A

  • Case studies of TPM activities and implementation

  • Examples of applications of TPM tools

Learning Objectives

  1. Understand the concept and management philosophy of TPM as a foundation for Lean transformation

  2. Learn the eight pillars of TPM activities, TPM implementation strategy, roadmap and step-by-step approach

  3. Learn the TPM tools and be able to identify and eliminate the six big equipment losses so as to improve Overall Equipment Effectiveness (OEE)

  4. Learn how to integrate Autonomous Maintenance with Planned Maintenance to improve equipment reliability

  5. Understand the roles of a TPM implementation organization and the critical success factors

Workshop Outline

1. Overview of TPM

  • What is TPM?

  • What TPM Is Not

  • Characteristics of TPM

  • TPM is a Paradigm Shift

  • TPM Goals

  • TPM Benefits

  • TPM Framework: 8 Pillars of TPM

 

2. TPM Foundations: 5S & Visual Management

  • 5S: Principles, Meaning & Practice Tips

  • Visual Management

  • How to set up Visual Management

  • 5S & Equipment Maintenance

  • 5S as the Basic Foundation of TPM

 

3. Key Tools for TPM

  • Small Group Activities

  • Fuguai Tagging

  • One-point Lessons

  • Suggestion Systems

  • TPM Activity Board

  • Team Morale Survey

4. Equipment Loss Analysis & OEE

  • Loss Structure in Production Activities

  • 6 Big Equipment Losses

  • Overall Equipment Effectiveness (OEE)

  • How to Identify & Eliminate the 6 Big Losses

  • How to Establish OEE System

 

5. Autonomous Maintenance

  • Introduction to Autonomous Maintenance

  • Forced Deterioration & Natural Deterioration

  • Definition & Concept of Autonomous Maintenance

  • 7 Steps of Autonomous Maintenance

  • Key Implementation Points of Autonomous Maintenance

  • TPM Excellence Criteria for AM

6. Planned Maintenance

  • Main Activities of Planned Maintenance

  • Implementation Guidelines for Planned Maintenance

  • Support from Planned Maintenance to AM

  • Key Steps Towards Zero Breakdown

  • 6 Steps of Planned Maintenance

  • TPM Excellence Criteria for PM

 

7. Focused Improvement

  • Key Steps of Kaizen Implementation

  • Analytical Tools – 5 Whys, Pareto Chart, Fishbone Diagram, 5W1H

  • Poka-yoke Techniques

  • Quick Changeover – the Core of SMED

 

8. Other TPM Pillars

  • Education & Training

  • Early Equipment Management

  • Quality Maintenance

  • Safety, Health & Environment

  • TPM in the Office

 

9. TPM Implementation

  • TPM Organization Structure

  • TPM Implementation Master Plan

  • Preparing for TPM Kick-off

  • Selection of TPM Model Line

  • TPM Excellence Awards

  • Critical Success Factors

 

10. JIPM TPM Excellence Award

  • About JIPM

  • Objectives of JIPM

  • Benefits of Applying for TPM Recognition

  • How is an Organization Selected as a TPM Winner?

  • JIPM TPM Award Categories

  • Assessment Criteria

Award of Certificate

Certificate of Attendance will be issued to participants who have attended at least 75% of the workshop

Duration

2 days

Get started with TPM training

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