Introduction

Total Productive Maintenance (TPM) is a proactive approach to equipment and facility management aimed at maximizing the overall effectiveness of production equipment. By focusing on the entire lifecycle of equipment, TPM involves all employees in maintaining and improving productivity, reducing downtime, and enhancing efficiency. This training course will teach participants how to implement TPM strategies across all areas of an organization to reduce maintenance costs, improve equipment reliability, and increase overall productivity.

Course Objectives

By the end of this course, participants will:

1. Understand the Fundamentals of TPM: Gain a thorough understanding of TPM principles, its objectives, and its significance in modern manufacturing environments.
2. Apply the Eight Pillars of TPM: Learn how to implement and benefit from the eight pillars of TPM to enhance maintenance practices, team involvement, and overall efficiency.
3. Develop Autonomous Maintenance Programs: Learn how to empower operators to take responsibility for routine maintenance tasks, thus improving equipment reliability and minimizing downtime.
4. Conduct Effective Preventive Maintenance: Understand the role of preventive maintenance in reducing breakdowns and prolonging the life of machinery.
5. Optimize Equipment Efficiency: Master the tools and techniques for measuring and improving Overall Equipment Efficiency (OEE) to maximize productivity.
6. Implement a TPM Roadmap: Gain insight into how to develop a structured TPM implementation plan and measure its success over time.
7. Foster a TPM Culture in the Organization: Understand how to build a culture of continuous improvement, cross-functional collaboration, and employee engagement in maintenance processes.
8. Address Common TPM Challenges: Identify potential barriers to TPM success and develop strategies to overcome them.

Who Should Attend?

This course is designed for professionals involved in manufacturing, maintenance, production, and operations management. It is especially beneficial for:

• Maintenance Managers who are responsible for equipment reliability and uptime.
• Production Managers looking to improve efficiency and reduce downtime in manufacturing processes.
• Operators who play an active role in the daily upkeep of machinery and equipment.
• Quality Managers aiming to enhance product quality through better equipment performance.
• Continuous Improvement Leaders who are focused on increasing productivity and minimizing waste.
• TPM Coordinators who need a comprehensive understanding of TPM to lead the initiative in their organizations.
• Lean and Six Sigma Practitioners looking to integrate TPM into their continuous improvement initiatives.

Day-by-Day Outline

Day 1: Introduction to Total Productive Maintenance (TPM)

• What is TPM?

  • Definition, history, and evolution of TPM.
  • The key goals of TPM: Maximizing equipment effectiveness, reducing downtime, and improving productivity.
  • TPM’s role in the broader context of lean manufacturing and continuous improvement.

• The Eight Pillars of TPM:

  1. Autonomous Maintenance: Empowering operators to perform routine maintenance tasks.
  2. Planned Maintenance: Establishing effective maintenance schedules to prevent breakdowns.
  3. Quality Maintenance: Ensuring equipment reliability to maintain product quality.
  4. Focused Improvement: Continuously improving equipment reliability and operational processes.
  5. Early Equipment Management: Designing equipment for reliability and ease of maintenance.
  6. Training and Education: Educating staff at all levels on TPM practices.
  7. Safety, Health, and Environment: Ensuring a safe and healthy work environment by maintaining equipment.
  8. TPM in Administration: Integrating TPM into non-manufacturing functions such as procurement and logistics.

• The TPM Roadmap:

  • Steps for initiating TPM in an organization.
  • Key success factors and challenges.
  • Developing a TPM implementation plan.

Day 2: Autonomous Maintenance

• The Concept of Autonomous Maintenance:

  • Role of operators in maintaining equipment and the benefits of involving them in the process.
  • Setting up daily, weekly, and monthly maintenance tasks for operators.
  • Developing standards for routine maintenance procedures.

• Training Operators for Autonomous Maintenance:

  • Creating training programs for operators to ensure they are equipped to take on maintenance tasks.
  • Identifying and addressing skill gaps to ensure successful TPM implementation.

• Operator-Initiated Problem Solving:

  • Encouraging operators to identify and solve minor issues before they become major problems.
  • Setting up mechanisms for reporting anomalies, defects, or maintenance needs.

• Practical Activity:

  • Hands-on exercise: Operators conducting simple maintenance tasks and documenting their activities.

Day 3: Preventive Maintenance and Planned Maintenance

• The Role of Preventive Maintenance (PM):

  • How preventive maintenance can help to reduce unexpected breakdowns and extend equipment life.
  • Creating a Preventive Maintenance (PM) schedule tailored to the needs of your equipment.

• Planned Maintenance Process:

  • Developing maintenance plans and schedules that minimize downtime and production interruptions.
  • Identifying the right balance between planned downtime and production.

• Measuring Maintenance Effectiveness:

  • Key performance indicators (KPIs) for tracking the effectiveness of preventive and planned maintenance.
  • Setting and evaluating PM performance metrics: Mean Time Between Failures (MTBF), Mean Time to Repair (MTTR), etc.

• Practical Activity:

  • Hands-on exercise: Developing a sample PM schedule for a selected machine or process.

Day 4: Measuring and Improving Overall Equipment Effectiveness (OEE)

• Understanding OEE:
  • What is OEE and why it is the most important metric in TPM.
  • The three components of OEE: Availability, Performance, and Quality.
• Calculating OEE:
  • How to calculate OEE for specific equipment or production lines.
  • Case studies: Examples of OEE calculations and analysis in real-world scenarios.
• Improving OEE:
  • Techniques for improving each of the OEE components: Reducing downtime, increasing speed, and ensuring quality.
  • Implementing corrective actions for equipment that is underperforming.
• Practical Activity:
  • Hands-on exercise: Analyzing OEE data and developing improvement strategies for a piece of equipment.

Day 5: TPM Implementation and Overcoming Challenges

• Building a TPM Implementation Team:
  • Key roles and responsibilities of the TPM team.
  • The importance of cross-functional collaboration in TPM.
• Overcoming Common TPM Challenges:
  • Identifying common barriers to TPM success (e.g., resistance to change, lack of management support, insufficient training).
  • Strategies for overcoming these barriers and ensuring the long-term success of TPM initiatives.
• Creating a TPM Sustainability Plan:
  • Ensuring that TPM practices are sustained over time and continuously improved.
  • Developing a strategy for monitoring TPM progress and performance.
• Final Action Plan:
  • Developing a personal action plan for implementing TPM principles in your organization.
  • Group discussions and sharing best practices from different industries.