Matec050 - Total Productive Maintenance Management Course

Total Productive Maintenance Management (TPM) Course is often the first place to begin the journey towards Lean Transformation because it creates a manufacturing environment of stability, reliability, and capability. A stable infrastructure is a critical foundation that must be built before more tightly coupled Lean practices can be successfully introduced and more importantly sustained.

Course Benefits

• Reducing unnecessary downtime due to breakdowns, minor stoppages, and quality problems.
• Enhanced maintenance and frontline employee engagement and collaboration.
• Systematically learning from equipment related problems so that root causes can be identified and addressed.
• Fostering productive dialogue between production managers, employees, and maintenance staff.
• This two-day workshop will introduce key TPM concepts, root cause analysis, and the strategies for a successful TPM pilot and wider journey

Training Modules

Day 1

• The History and Evolution of Maintenance in the Context of Lean Management
• The 5 Pillars of TPM (Continuous Improvement in OEE, Maintenance Asset Care, Operator Asset Care {Autonomous Maintenance}, Skills Development, and Early Equipment Management)
• The 4 Core TPM Metrics for the Attainment of Flow and the Practices Deployed to improve these metrics

The TPM Model of:

• Measurement Cycle (Historical Analysis, OEE, 6 Losses)
• Condition Cycle (Criticality Assessment, Condition Appraisal: Spot the Rot, Refurbishment Plan and Spares, Asset Care)
• Problem Prevention Cycle (Best Practice and Problem Prevention)
• TPM Model Practical Exercise

Day 2

• TPM Current State Diagnostic Audit Exercise
• FMEA to Mitigate the 80/20 Breakdown Risks and Exercise
• Predictive Maintenance – Methods of Predicting Time between Equipment Failures
• Cultural Considerations and Team Working
• 5S Workplace Organization and Impact on TPM (the surprising root cause of 40% of equipment breakdowns)
• Quick Changeover and TPM
• Continuous Maintenance Improvement Visual Management System
• TPM Implementation Road-map Exercise

This course is also available as an on-site customized course

Target Audience

This course is designed for all levels of Technical Personnel in the oil and Gas Industry as well as in Chemical and Process Industries but will greatly benefit:

• Technical Personnel in charge of Production
• Maintenance and Operations Engineers
• Operators
• Supervisors
• Engineering and Production Managers

Award of Certificate:

At the end of the programme, only participants who have succeeded in completing all assignments shall be awarded a certificate.