Training Course Program
TPM - Total Productive Maintenance - 4-day course
how to maximise overall equipment effectiveness, minimising losses and assuring optimal value generation through plant and machinery in the manufacturing industry
course contents and main topics
How to achieve an industrial Operational Performance of world-class calibre. What is World-Class Manufacturing and how does TPM relate to it. How TPM - Total Productive Maintenance will contribute to very high levels of productivity, output quality and value generation through Plant, Equipment and Machines (more »).
Industrial competitiveness today is based on the motto: "Methods first, then Technology". What are the modern principles of Plant, Equipment and Machinery Management. How to prevent major technological mistakes (the "super-star-galactica" cul-de-sac....). What is the ideal Plant layout for real Flow Production and healthy Lean Manufacturing (more »). How to deploy the Systematic Elimination of Waste discipline in medium/heavy mechanised/automated operations (more »). How to harmonise People and Machines in a productive system geared to produce high levels of added-value
. What are the main differences between "traditional" TPM and today's TPM.
Today's TPM goals: maximisation of Equipment Effectiveness and added-value - total elimination of waste related to Equipment - high involvement of people selecting designing, operating and maintaining Equipment - "life-cycle" management of Equipment - optimal management of the Industrial Safety and Environment Protection parameters.
How to calculate Overall Equipment Effectiveness (OEE)and associated added-value. How to identify the 6 Big Losses associated with Plant and Equipment. Movie time: how to identify waste of manpower next to Machines and Equipment.
Classification of Losses related to Equipment. How to identify and distinguish between chronic Losses and sporadic Losses. Why certain Losses go undetected, unmeasured, unattended, overlooked: how to instil a new mentality and industrial culture in personnel at all levels. Presentation and in-depth analysis of the main methods and techniques used today for Losses elimination or drastic reduction. The PM Analysis: a powerful tool to fight chronic Losses.
Fighting Plant breakdowns: today's approach is "no machine should break down". How operators can contribute to the target. The TPM approach to zero-breakdowns.
Fighting set-ups and change-overs: the Quick Change-Over technique and the Instantaneous Change-Over approach. How to progress towards smaller lots and smaller production batches through faster change-overs (more »).
Fighting start-up Losses. Fighting Machines idling and minor stoppages. Fighting poor productivity due to reduced machine speed/capacity. Eliminating poor quality of output product: how to achieve the zero-defects target through Poka-Yoke methods (more »).
Deep involvement and accountability of operators is the main TPM secret: what is Autonomous Maintenance, the "heart" of TPM. Basic principles of Autonomous Maintenance. Education and Training for TPM - TPM for Production Personnel and Workshop Leaders - TPM for Technical/Engineering Departments: a new approach to Plant selection and design.
The new role of the Maintenance Department. How to increase co-operation and introduce integration between Production and Maintenance personnel. How to restructure an enterprise to modern concepts of multi-skill and multi-function personnel. How to reduce significantly all manpower-related waste.
Preventive Maintenance today: Standardisation - Planning - Recording. Maintenance Economics: how to reduce drastically the overall Maintenance expenditure.
New frontiers in Plant Maintenance: Predictive Maintenance - Maintainability Improvement - Maintenance Prevention.
Spare Parts Management. Plant Management Economics. Budgeting. Industrial Cost Control in "real-time".
How to plan, introduce and launch a TPM project. Movie time: how to increase OEE from 30% to over 90% in 6 months.
How to measure TPM Effectiveness. How to monitor progresses through a radar-chart
The importance of Top Management commitment for real improvement in enterprise's Operational Performance through TPM. The second Industrial Revolution: how to face the years 2000 challenge.
Duration: 32 hours
No industry, today, can perform any operational processing without equipment.
In the ideal productive concern, equipment should be operating at 100% capacity 100% of the available time, producing value. Total Productive Maintenance (TPM) is the state-of-the-art discipline that leads, in a process of continuous, systematic improvement, towards the ideal target (0 equipment downtime, 0 defects and 0 safety problems).
This very comprehensive and intensive course is structured to give a complete, "hands-on" picture of today's TPM.
The objectives of this course include (but are not limited to) the following:
- to present to participants the World-Class Manufacturing scenario and the relationship with TPM and Lean Manufacturing, illustrating the main differences between "traditional" and "today's" TPM
- to show with practical examples the importance of a modern approach to industrial performance based primarily on people, then on methods and only thereafter on technology
- to give an in-depth presentation of today's TPM and study its approach, principles, tools and techniques
- to illustrate the new relationship between production and maintenance personnel, based on integration rather than division
- to illustrate today's principles and methods of Plant Management and study its main technical and economical aspects
- to supply participating delegates with practical guidelines for planning and introducing a valid TPM program within their enterprise, illustrating benefits as well as constraints and necessary prerequisites
- to present simple but effective tools to measure, at any moment in time, the results achieved so far through a TPM program and identify the gap still to be filled
This course is very interactive and supplemented with abundant practical exercises and case studies
Operations Managers, Plant Managers and Engineers, senior and middle level Maintenance Managers, senior and middle level Production Managers, Quality Managers and Technical Managers from manufacturing enterprises.
This course is designed specifically for the Manufacturing Industry.
A 2-day workshop on TPM for the Manufacturing Industry is also offered. For details please click here.
The TPM workshop program for the Project/Construction Industry is here.
The TPM workshop program for the Service Industry is here.
You are welcome to request further clarifications about this course - please be as specific as possible. Just contact Carlo Scodanibbio
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