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. Understand the Autonomous Maintenance process and how to improve equipment reliability

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

Workshop Outline

  • Introduction to TPM

    • What is TPM?

    • What TPM Is Not

    • TPM Principles

    • TPM is a Paradigm Shift

    • Why is TPM Important?

    • TPM Goals

    • Benefits of TPM

    • Overview of the TPM Pillars & Activities

  • TPM Foundations: 5S & Visual Management

  • TPM Tools

    • Small Group Activities

    • Fuguai Tagging

    • One Point Lessons

    • Activity Boards

    • Suggestion Systems

  • Six Big Equipment Losses & Overall Equipment Effectiveness (OEE) 

    • Breakdown Losses

    • Setups & Adjustment Losses

    • Reduced Speed Losses

    • Minor Stops & Idling Losses

    • Defects & Rework Losses

    • Startup & Yield Losses

    • 3 Key Components of OEE

    • "World-class" OEE

    • Equipment Losses & OEE

    • Calculating OEE

    • Strategies for Zero Breakdowns

  • The Eight Pillars of TPM

    • Autonomous Maintenance

    • Planned Maintenance

    • Focused Improvement

    • Early Equipment Management

    • Quality Maintenance

    • Education and Training

    • Office TPM

    • Safety, Health & Environment

  • TPM In Focus: Integrating AM & PM Activities to Improve Equipment Reliability



  • TPM Implementation

    • TPM Organization Structure, Roles & Responsibilities

    • TPM Implementation Master Plan

    • 12 Steps of TPM Implementation (Nakajima)

    • TPM Audits & Self-assessment

  • Overview of JIPM TPM Excellence Award

    • Purpose of the TPM Excellence Award

    • Using the TPM Excellence Award Criteria for Organizational Self-assessment

    • Applying for TPM Recognition

    • JIPM TPM Award Categories

    • Assessment Criteria

    • TPM Metrics

  • Sustaining TPM

    • How to Sustain TPM

    • Critical Success Factors

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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