Total Productive Maintenance (TPM) Course

In the present high stress and turbulent business environment, well run organizations strive to continually enhance their capabilities to create excellent value for the consumers by improving the cost effectiveness of the operation. Maintenance is thus a vital support function in business, especially increasing large investment is been required in physical asset. Production line may be running and yet the output may be very low. Yield losses consist of losses due to reject and poor start up behavior in the line producing the product. These losses lead to low value of Overall Equipment Effectiveness (OEE) which provides an indication of how the production process is. TPM helps to raise the value of the OEE by supplying a structure to facilitate the assessment of those losses.

 Course Objective:

At the end of this course each participant will be able to:

• Understand the concepts and philosophy of Total Productive Maintenance; including Equipment related Losses, OEE Measurement and Reliability Centred Maintenance Integration.
• Develop, implement and sustain a reliability based Business Centred Maintenance programme at minimum cost using shop floor personnel.
• Reduce life cycle support costs by reducing the adverse effects of poor design on maintenance and logistics.
• Understand the building blocks of a World Class Manufacturing organization and their synergistic relationships.
• Measure the effectiveness of Maintenance Management and its related Computerized Maintenance Management System (CMMS) in their organization.
• Understand how to realize a meaningful return on investment of your CMMS.

Target Audience

• Plant Engineers
• Maintenance Managers and Supervisors
• Facilities Manager and Supervisors

Methodology

In addition to the generic case studies presented during the course, exercises will be developed from the delegate’s own facilities, equipment and history. It was found that by using this method of instruction, correlation from the theoretical to the practical can be made much quicker in any future analysis performed by the participants.

Content

• Introduction
• World Class Manufacturing
• Total Productive Maintenance (Overview)
• Why TPM?
• Goals of TPM
• Benefits of TPM to the company
• Comparison between TQM and TPM
• Types of maintenance
• TPM target and uniqueness
• Overall Equipment Effectiveness
• Steps for achieving 3 zeros
• Stages in the introduction of TPM in an organization
• Implementation of Total Productive Maintenance
• Eight pillars of TPM
• Aims of eight pillars
• 5S
• Autonomous Maintenance
• Early Equipment Management
• Quality maintenance
• Training
• Office TPM
• Safety and Environmental Management
• Results of a good TPM implementation
• Conclusion