Total Productive Maintenance

Por: Swayam . en: , ,

  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
 

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