TOTAL PRODUCTIVE MAINTENANCE: Maximise Efficiency of Production and Engineering Facilities

Workshop Objective

1. The Total Productive Maintenance Ideals Zero Defects, Zero Breakdown, Zero Accidents and Zero Waste

2. The Fundamentals of Total Productive Maintenance 5 S Technique

3. Eight Pillars to Ensure Total Productive Maintenance Success

4. Develop Optimum Workshop Conditions Human-Machine System

5. Identify the SIX Major Losses affecting Company Production

6. Calculate the Losses on the Manufacturing Floor

7. Develop and Implement a Preventive Maintenance Schedule Ensure its SUCCESS!

8. Plan out the Maintenance Activities and Schedule Maximise Machine Productivity

Target Participants

All Maintenance Supervisors, Executives, Engineers and People who interested to Increase Machine/Equipment Productivity

Outline 

Part A TOTAL PRODUCTIVE MAINTENANCE PROFILE

1.       What is Total Productive Maintenance and its Contribution to Productivity

2.       Integrate Total Productive Maintenance to Continuous Improvement and Quality Improvement Programmes

3.       The 4 Total Productive Maintenance Ideals – Zero Defects, Zero Breakdown, Zero Accidents and Zero Waste

Part B  TOTAL PRODUCTIVE MAINTENANCE DEVELOPMENT

1. TOTAL PRODUCTIVE MAINTENANCE DEVELOPMENT

A.      Development of TPM Support the Production of the Product

B.      The American Model and Japanese Model – How TPM evolved!

C.      Understand the Use of Total Productive Maintenance in Singapore/Malaysian Context – What all companies should emulate

2. 5’S –FUNDAMENTAL OF TOTAL PRODUCTIVE MAINTENANCE

A.      Implement SEIRI Schedule, Fixing, Identifying, Making and Attaching, Taking Action on Red Tag Items

B.      Implement SEITON Workplace Organisation with Colour Lines and Storage Organisation.

C.      Implement SEISO Consolidate Daily Cleaning Procedures and Make Cleaning and Checking Habitual

D.      Implement SEIKETSU Tools for Seiketsu and develop a 5S – Housekeeping Checklist.

E.      Implement SHITSUKE Photo Display, 5S Corners, 5S Contests and 5S Competition.

3.  ZERO BREAKDOWN

A.      Why do Breakdowns Occur and Techniques Eradicate Causes of Breakdowns

B.      5 Points Improvement Strategies to Avoid Breakdowns

·       Cleaning, Tightening Nuts and Bolts, Complete Lubrication

·       Proper Use of Equipment

·       Reveal Hidden Defects, Restore to Original Conditions

·       Reconsider Equipment Design

·       Improve Equipment Maintenance

C.     Practical 4 Step Plan towards Zero Breakdown

·       Reduce Excess Wear and Tear

·       Improve Design Weak Points

·       Regular Maintenance

·       Forecast Maintenance

4.  EIGHT PILLARS OF TOTAL PRODUCTIVE MAINTENANCE

A.      Kobetsu Kaizen Improve Quality, Delivery, Cycle Time, etc.

B.      Autonomous Maintenance Small Group Activity to Resolve Daily Problems

C.      Planned Maintenance Structured and Organised Maintenance System

D.      Skills Training for Operators and Maintenance Make Minor Repairs

E.      Early Equipment Product and Process Management System Effective Feedback to Improve R&D and Minimise Rejects

F.      Develop Administrative Systems Total Productive Maintenance in Office

G.      Ensure Complete TPM with Safety/Hygiene and Environment System

5. OPTIMUM WORKSHOP CONDITIONS  HUMAN-MACHINE SYSTEM

A.      Improve Overall Quality of Workplace Conducive Environment, Layout, Material, Lighting, etc

B.      Changing Equipment – Upgrading, Cleaning, Checking, Abnormality, Things to Improve, etc.

6. THE SIX BIG LOSSES

A.      The SIX Big Losses on the Manufacturing Floor Losses to AVOID!

            i.      Breakdown Losses Failure Function

            ii.     Set-up and Adjustment Losses Change of Toolings

            iii.    Idle and Minor Stoppage Losses Temporary Breakdown

            iv.     Reduce Speed Losses Reduced Function Quality Defects and Rework Wrong Specifications

            v.      Start-up/Yield Losses Long Stoppage/Restart Work

B.      Eliminate/Minimise SIX BIG LOSSES to achieve Total Productive Maintenance Ideals

7.  EQUIPMENT PRODUCTIVITY LOSS CALCULATION METHODS

A.      Identify Productivity and Quality Improvement Targets Suitable Targets for your Company

B.      Calculate Overall Equipment Efficiency How Productive is your Equipment

C.      Practical Loss Calculation Methods and Improvement Targets

D.      Practical Approach to Chronic Loss Improvement – Chronic and Sporadic Events

E.      Implement Preventive Maintenance Analysis and The Seven Step Approach.

8.  AUTONOMOUS MAINTENANCE

A.      What is Autonomous Maintenance and How it Improve Production Downtime

B.      The SEVEN Step Technique in Autonomous Maintenance

C.      Implement Total Productive Maintenance The TWELVE Step approach

D.      Operators Role in Preventive and Corrective Maintenance to ensure Smooth Production Flow

E.      Basic Skills and Procedures in Maintenance – Cleaning, Checking, Oiling, Tightening.

F.      Identify Types of Motors/Pumps and their Structures

G.      Identify Key Points in Motor/Pump Inspection and Cleaning

H.      Implement Corrective Maintenance Techniques – Equipment Improvement to Minimise Problem Recurrence

I.      Workshop to Implement Total Productive Maintenance in your Organisation – Maximise Productivity and Quality