TOTAL PRODUCTIVE MAINTENANCE (TPM)

Introduction

This program focuses on the practical aspects of Implementing Total Productive Maintenance to achieve maximum machine utilization or "Zero Machine Downtime".

Course Duration

2 Days.

Objectives

• At the end of this program, participants should be able to:
  
• Appreciate the Benefit of "Full machine utilization - Zero Down Time"
  
• Apply the most effective and efficient methods in maintaining machines
  
• Establish the necessary Plant Maintenance skills in their organizations
  
• Establish the implementation plan for TPM in their organizations
  

Methodology

This course is conducted through lecture and informal group discussion Participants shall draft out a suitable implementation plan for their organizations at the end of the session. Appropriate training video will also be used in this session.

Who Should Attend

Supervisors, Executives, Engineers and Managers involve in Quality, Process, Planning and Production.

Resource Person

Sim Lam Thong has a bachelor degree in Mathematics/Physics and has more than 14 years of vigorous involvement in TQC/TPM activities, problem solving and Management training. He is specialized in quality, TWC, SPC, productivity and TPM training/Consultants, Industrial Statistical Application and Design of Experiments Training and implementation. Sim has been consulting for many multinationals such as Hewlett Packard, Seagate, ICI Products, Acer and many more.

Contents

Module A

Introduction to TPM ( Total Productive Maintenance)

History & origin of TPM

• Differences between PM (Preventive Maintenance) & TPM
  
• TPM Definition
  
• Company-wide Implementation of TPM, Roles & responsibilities of each category of employees
  
• Concepts of JIT & TPM and their linkages
  
• Eight Pillars of TPM (Introduction)
• TQC & TPM Comparison & linkages

Module B

Concepts of Production Efficiency & Kobetsu Kaizen

1 - What is production efficiency?

2 - Sixteen major losses that impede production efficiency.

• Seven major losses that can impede equipment efficiency.
  
• Losses that can impede equipment operating rate.
  
• Five major losses that can impede human work efficiency.
  
• Three major losses that can impede effective use of production resources.
  

3 - Comparison of Chronic Losses & Sporadic Losses.

• Characteristic of Chronic & Sporadic Losses.
  
• Implication & Effect of Chronic & Sporadic Losses.
  

4 - Concepts of improvement.

• Basic concepts of improvement.
  
• Concepts of restoration & minor defects.
  
• Concept of ideal condition.
  
• Alignment, Adjustment & Regulation.
  
• Pursuit of Skills.
  
• Calculation of OEE (Overall Equipment Effectiveness)

Module C

Autonomous Maintenance (Jishu Hozen) - 7 steps

1 - What is Jishu Hozen (Autonomous Maintenance)

2 - Implementing Jishu Hozen

• Roles of Operators & Maintenance personnel
  
• Activities of Maintenance personnel
  
• Activities of Operators
  
• Classification & Methods of Maintenance sharing
  

3. Seven steps of Jishu Hozen

• Step 1 - Initial cleaning
  
• Step 2 - Counter measure for source of problems & difficult to reach location
  
• Step 3 - Establish tentative Jishu Hozen standards.
  
• Step 4 - Overall inspection
  
• Step 5 - Autonomous inspection
  
• Step 6 - Standardization
  
• Step 7 - Autonomous Maintenance

4 - Implementation master plan & target setting

5 - Twelve key points to successful Iimplementation of Jishu Hozen

6 - Jishu Hozen Diagnosis

7 - Jishu Hozen in various industry sectors such as electronics, fabrication etc.

8 - Forming Small Group Activities to perform Jishu Hozen