Total Productive Maintenance

  Module 1: “Introduction to TPM”  

• Case Study:NIKE’S 2001 PLANNING SYSTEM PERPLEXITY
• What does PM means?
• PM as a Postponed Maintenance
• What is TPM?
• What does TPM stands for?
• History of TPM
• Difference between TQM & TPM
• Need of TPM in organization
• Principles of TPM
• TPM-A Zero sum game
• Second Video-
• Goals and objectives of TPM
• Difficulty in implementation of TPM
• The TPM Paradigm Shift
• TPM is a team effort
• Expectation from TPM
• Pre-TPM checklist
• Roles and Responsibilities in TPM
• The Operators role
• The Specialists role
• Improvement teams role

Module 2: TPM pillars

• TPM-8 pillars Introduction
• Pillar 1: Autonomous maintenance (JishuHozen)
• Pillar 2: Focused Improvement (Kobetsu Kaizen)
• Pillar 3: Planned Maintenance
• Pillar 4: Quality Maintenance
• Pillar 5: Early Equipment Maintenance
• Pillar 6: Education and Training
• Pillar 7: Safety, health And Environment
• Pillar 8: Office TPM
• Case Study

Module 3: Maintenance under TPM

• Autonomous Maintenance
• Definition
• Goals & objectives of autonomous maintenance
• 7 Steps to autonomous maintenance
• Step-1: Initial clean-up using 7S system
• Step-2: Repair sources of defects
• Step-3: Develop standards & data collection
• Step-4: Standards for monitoring key process parameters
• Step-5: Train operators on function & troubleshooting
• Step-6: Provide spare parts &tools orderliness
• Step-7: All out autonomous maintenance
• Breakdown Maintenance
• Definition
• Goals and objectives of breakdown maintenance
• 3 Steps to standardized breakdown work
• Step-1: Identify root cause
• Step-2: Eliminate cause
• Step-3: Standardize preventive work to eliminate reoccurrence
• Transition of breakdown maintenance to preventive maintenance

Module 4: Maintenance under TPM (contd.)

• Planned Maintenance
• Definition
• Goals and objectives
• 7Steps of planned maintenance
• Step-1: Support to ‘Autonomous Maintenance’ activities
• Step-2: Evaluation of breakdown status
• Step-3: Reverse deterioration & correct weaknesses
• Step-4: Build an ‘Information Management’ system
• Step-5: Build a ‘Periodic Maintenance’ system
• Step-6: Build a ‘Predictive Maintenance’ system
• Step-7: Evaluate the planned Maintenance system
• Upstream Maintenance
• Definition
• Goals and objectives
• Short steps to maintenance excellence

Module 5: TPM losses

• Definition of losses
• Causes of losses
• 6 Big losses of TPM
• Breakdown losses
• Setup and adjustment losses
• Idling and minor stoppage
• Reduced Speed losses
• Quality defects and rework
• Start-up losses
• Basic quality management tools from TPM
• Definitions of AR, QR, PR & OEE
• Zero Accident
• Definition of zero accidents
• Steps in zero accidents

Module 6: Prerequisites of TPM

• 9 Essentials of TPM
• 7 Steps of operator maintenance
• Initial cleaning
• Countermeasures at the sources of problems
• Cleaning and lubrication standards
• General inspection
• Autonomous inspection
• Organization and tidiness
• Full autonomous maintenance
• The new roll for the maintenance department

Module 7: TPM Education& Training

• GEMBA Workshops
• Key indicators
• Strive workshop and “7S” Initiatives
• Visual management
• Process flow
• Autonomous work checklists
• Display key process parameters
• One-Point lessons
• Tools management
• Suggested Reading

  Module 8: Measuring TPM effectiveness

• The philosophy of setting goals
• Types of indicators
• Evaluating TPM
• Overall Equipment efficiency
• Definition of OEE
• OEE Factors
• The Role of OEE in Total Productive Maintenance
• How to calculate?
• How To Improve Overall Equipment Effectiveness (OEE)
• Direct & Indirect benefits of TPM

  Module 9: Predictive maintenance

• Definition of Predictive maintenance.
• Benefits of Predictive Maintenance
• Risks associated with poorly maintained equipment
• Equipment condition monitoring thro Statistics
• Analyzing data
• Determining maintenance needs
• Maintenance planning, execution & reporting