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Total Productive Maintenance

3 day Training

Dates: 06 – 08 August 2024
Locations: Johannesburg, South Africa
Platform: Available In-Class / Online

Price: Available on Request

This is a Non-accredited Course

Course Introduction

Total Productive Maintenance is a world-class approach to equipment management that involves everyone, working to increase equipment effectiveness. The TPM approach allows you to deploy a comprehensive set of tools and techniques to eliminate all losses across a whole organisation and throughout the value stream.

 

TPM involves the capabilities of the whole workforce to ensure effective and sustainable improvements are implemented. Improvements to the organisation are made by improving the two core elements of people and equipment. TPM brings maintenance into focus as a necessary and vitally important part of the business. It is no longer regarded as a non-profit activity.

 

Down time for maintenance is scheduled as a part of the manufacturing day and, in some cases, as an integral part of the manufacturing process. The goal is to hold emergency and unscheduled maintenance to a minimum. Implementing TPM establishes processes and metrics that focus attention on minimizing the non–value-added tasks. The resulting increase in productivity applies not only to the equipment, but to the people working in the manufacturing system as well.

Course Objectives

  • An understanding of different types of Maintenance

  • An understanding of the techniques to eliminate wastes.

  • An understanding of the 8 Pillars of TPM and their impact on equipment reliability

  • An understanding of the techniques and methods that promote the company-wide support for a successful TPM implementation.

  • Awareness of the value of the TPM implementation process.

  • How to stabilize work station conditions and significantly reduce equipment and system failures.

  • How to simplify routine maintenance and inspection procedures.

  • Improve effectiveness of preventive maintenance and promote equipment restoration and reliability.

  • How TPM leaders can improve operators’ skills in conducting a variety of improvement activities to achieve equipment reliability.

  • Development of TPM Leaders to promote and co-ordinate improvements.

  • Understand how to Implement TPM by following our Step-by-Step Roadmap

  • Recognising and solving the root causes of your equipment failures.

  • Knowing when to use reliability engineering to get the most benefit for your operation.

  • Realising where reliability engineering can deliver simple and low-cost reliability improvements to you.

Who should attend?

Total Productive Maintenance involves everyone in the organization from operators to senior management in equipment improvement. It encompasses all departments, and the following departments should attend training:

  • Maintenance artisans and managers

  • Operations managers and supervisors

  • Planner & Schedulers

  • Design Engineering

  • Project Engineering

  • Construction Engineering

  • Purchasing/Procurement

  • Plant and Site Management

  • Production Supervisors

  • Machine Operators with experience and earmarked to be developed to supervisor

Training methodology

Training Methodology

Our diverse instructional approaches ensure effective learning:

– Lectures & Presentations: Engage with expert-driven, stimulating content.
– Course Material: Access well-crafted supporting resources.
– Group Work: Collaborate on discussions and case studies for practical insights.
– Workshops & Role-Play: Participate in immersive, scenario-based activities.
– Practical Application: Focus on applying theoretical knowledge in real situations.
– Post-Training Support: Receive extensive support after training for skill implementation.

Training Outline

Day 1

Module  1: Maintenance in perspective

  • Introduction to Maintenance

  • The Objective of Maintenance

  • Overview of the Types of Maintenance

  • Breakdown maintenance

  • Preventive maintenance

  • Autonomous Maintenance

  • Reliability Centered Maintenance

  • Planned Maintenance

  • Equipment design and predictive maintenance

  • Equipment Effectiveness and Availability

  • Overall Equipment Effectiveness (OEE)

  • Performance/output Efficiency

  • Group Discusions:

    • The 12 critical resources required in maintenance

    • The 12 criterions for teamwork

Module 2: Fundamental Requirements of Effective Maintenance

Discussion of the basic tasks that will result in reliable plant systems, including:

  • Human Senses

  • Using Sensor Technology

  • Careful Inspections

  • Establishing Thresholds points

  • Machine Lubrication

  • Calibration to keep measurement and control instruments within limits

  • Lock Out Tag Out Procedures (LOTO)

  • Statistical Process Control basics

  • Scope of Responsibility: Primary and Secondary Maintenance roles

Module 3: Introduction to Total Productive Maintenance

  • The Definition of Total Productive Maintenance

  • The Impact of Total Productive Maintenance

  • The History of TPM

  • How TPM compliments the Lean Philosophy

  • Similarities and differences between TQM and TPM

Day 3

Module 4: Objectives and benefits of TPM

  • Objectives of TPM

  • Eliminating Process Losses

  • Benefits of TPM

    • Reduced Variation

    • Increased Productivity

    • Reduced Maintenance Costs

    • Reduced Inventory

    • Improved Safety

    • Improved Morale

Module 5: The 8 Pillars of TPM

      5S: A foundation for well-running equipment

      Pillar 1:  Achieve autonomous maintenance (Jishu Hozen)

      Pillar 2: Focussed Improvement (Kobetsu Kaizen)

      Pillar 3: Planned Maintenance

      Pillar 4: Training and Education

      Pillar 5: Early Management

      Pillar 6: Quality Maintenance

      Pillar 7: Office TPM

      Pillar 8: Safety, Health and Environment

Module 6: Measuring TPM Effectiveness

  • TPM Metrics

  • Overall Equipment Effectiveness (OEE) and the 6 big losses

  • TPM Activities

  • TPM Problem Solving by using the 7 quality control tools

Day 3

Module 7: Implementing an effective Lubrication Program

  • Overview of Plant Lubrication

  • Lubrication: Duties and Responsibilities of Management and Employees

  • The activities to achieve and carry out an effective lubrication program

  • Establishment of Lubrication Schedules and Improvements in selection and application of Lubricants

Module 8: TPM Implementation Guidelines

       Step 1: Announcement of TPM

      Step 2: Launch a formal education program

      Step 3: Create an organizational support structure

      Step 4: Establish basic TPM policies & quantifiable goals

      Step 5: Outline a detailed master deployment plan

      Step 6: TPM kick-off

      Step 7: Improve the effectiveness of each piece of equipment

      Step 8 : Develop an autonomous maintenance program for operators

      Step 9: Develop a planned or preventive maintenance program

      Step 10: Conduct training to improve operation and maintenance skills

      Step 11: Develop an early equipment management program

      Step 12: Continuous improvement

 

Module 9: TPM Success Factors and Enablers

  • Management Support

  • Focused Approach

  • Operator Ownership

  • Just-In-Time Training

  • Integrated Processes and Schedules

  • Overcoming the barriers to effective TPM Implementation

  • Final Recommendations for Improvement

Practical Case Study: Complete an Activity of sample Case study of TPM Implementation

All forms will be provided in printed format, or in Excel / Word format for practical exercises.

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