Total Productive Maintenance

3 day Training

Dates: 11 – 13 November 2024
Locations: Grayston Ridge Office Park, Sandton
Platform: Available In-Class / Online

Price: Available on Request

Claim 3 CPD Points

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?

Prospen Africa’s 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

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