Total Productive Maintenance (Online Training)

Course Objectives

Product cycle-time is always an issue in manufacturing that leads to delivery issues. One of the main contributors is high equipment downtime. And in many cases, manufacturers blamed on their aging equipment. Though this is partly the cause, human intervention such as handling, care and loading are more directly impact to the equipment irregardless of its age. Therefore new and good equipment can also be damaged with the lack of proper support system.

Hence, proper equipment upkeep and handling can significantly help to improve production cycle-time. The Total Productive Maintenance, TPM system is a highly effective collaborative system that merge both the user (production) and the default caretaker (maintenance) to provide equal attention and responsibilities towards the equipment. This shall discard the traditional abuse of “I use, you repair” production mindset to “I use, I care” mindset.

Participants will learn how to:

• To achieve higher productivity through reduced unplanned downtime
• To provide better care for equipment to last for production entire lifespan
• To continuously improve equipment efficiency through OEE & MTBF analysis
• To cultivate a collaborative system between production and maintenance that uphold high level of responsibility towards equipment care and handling
• To improve overall Quality, Productivity, Cost, Profit, Morale & Customer Satisfactions

Target Audience

• Engineering, Maintenance & Production
• Managers, Executives & Supervisors
• Those who need to reduce downtime & improve productivity

Methodology

This Live Online / Virtual Training session will be conducted via a Live Streaming Platform in which the trainer will use interactive lecture and slide presentation to cover the modules stated below.

Course Modules

• Module 1: Introduction
  – Context Setting
  – Course introduction
  – Discussion : Common Issues

• Module 1: TPM Overview
  – Definition of TPM
  – Impact of TPM
  – 5 Points Definition of TPM
  – Basic Principle For Equipment Maintenance
  – Measurement of TPM effectiveness
  – Goals of TPM
  – Principles of TPM
  – Types of Maintenance
  – 3 Aspects of Equipment Maintenance
  – 5 Elements of Production
  – Aims of TPM
  – TPM is about Change
  – Changing the way we think & do

• Module 3: Approach To Equipment Effectiveness
  – TPM Aim to Eliminate Losses
  – 6 Major Equipment Losses
  – Overall Equipment Effectiveness
  – Availability
  – Performance & Efficiency
  – Rate of Quality Products
  – OEE Calculation
  – Analysis of Losses
  – Ideal Conditions
  – Approach to Equipment Effectiveness

• Module 4: Chronic Losses
  – Definition of sporadic and chronic losses
  – Approaches in tackling sporadic and chronic losses
  – Mean Time Between Failure, MTBF
  – Mean Unit Between Assist, MUBA
  – Why-Why Analysis

• Module 5: TPM Pillars, PM & AM
  – Overview of TPM pillars
  – Understanding of TPM pillars
  – Approach in implementing the TPM pillars

• Module 6: Planned Maintenance
  – Planned Maintenance, PM
  – Aim of PM
  – Barrier to PM
  – Overcoming the Barrier of PM

• Module 7: Autonomous Maintenance
  – Autonomous Maintenance, AM
  – Objectives of AM
  – Purpose of AM
  – Aim of AM
  – Simple AM Steps
  – Steps to Perform AM
  – Success Factors of AM

• Module 8: Autonomous Maintenance Activities
  – Begin with 5S
  – AM Cleaning Principles
  – CILR
  – Initial Cleaning
  – Hard to Clean Areas
  – Source of Contamination
  – Inspection
  – Vibration & Temperature measuring
  – AM Tools & Techniques
  – Success Factors of AM
  – Abnormality Identification & Rectification
  – One-Point-Lesson

• Module 9: Implementing TPM
  – 12 Steps to TPM development
  – PM Development Process
  – Continuous Improvement – Suggestion Scheme
  – TPM Implementation Road-map
  – TPM Implementation Success Factors
  – Trend Analysis

• Module 10: Reflection
  – Q&A & Feedback
  – Learning Summary
  – Endgame