Total Productive Maintenance 1 day (workshop) /
Implementation time varies on size of project
Breakdowns cost big-time. Total Productive Maintenance (TPM)
programs are like an insurance policy for manufacturers. In the
1950s and '60s, Japan's manufacturing industry was in the midst
of a rapid program of constructing additional production
facilities. As this buildup proceeded, it grew increasingly
clear that productivity and product quality in the manufacturing
industry were strongly affected by the condition of plants and
facilities. To control these factors, techniques of plant
maintenance were introduced from the United States. At the heart
of plant maintenance was Preventive Maintenance, which would
later inspire a method called Productive Maintenance, developed
at General Electric to improve productivity. Plant maintenance,
along with its central principle of Preventive Maintenance, led
to the formation of specialized maintenance organizations,
establishment of plant maintenance systems, and development of
diagnostic technologies. Through activities to raise efficiency
in maintenance work, plant maintenance provided a significant
contribution to the evolution of the process industry. At the
same time, however, these trends reinforced a division of labor
between equipment operation and equipment maintenance. In
effect, this caused equipment operators to become estranged from
the equipment it was their task to operate. These forces have
been traditionally antagonistic: production blames maintenance.
TPM helps bridge this gap as well as ensuring that machines
are ready to produce at any time. It also stretches scarce
maintenance technician resources. TPM starts by creating a
much-needed bonding and cooperation between maintenance crews
and production operators, supervisors and management.
Course Description:
In this workshop participants become familiar with TPM, a
systematic approach for minimizing machine downtime resulting
from unexpected breakdowns. We will emphasize the role of the
machine operator who becomes involved with routine checks and
fine-tuning. We will also demonstrate how TPM enables machinery
to operate more efficiently and reliably by sharing the
knowledge of skilled tradesmen with the operators, standardizing
minor preventive methods, while freeing-up valuable time for the
skilled tradesmen to pursue further technical activities.
Learning Objectives:
After the Workshop participants will be able to:
- Develop a partnership between maintenance and production;
- Recognize the major sources of equipment function loss;
- Reduce breakdowns and other losses by improving shop-floor
maintenance;
- Restore equipment to higher levels of performance with
operator input and involvement;
- Promote rigorous preventative maintenance by shop-floor teams;
- Eliminate fire-fighting and focus on diagnosis, failure
prevention, increased reliability, and longer equipment life;
and
- Reduce total manufacturing costs while raising quality.
Who Should Attend:
Value Stream Managers, Plant or Operation Managers, Maintenance
personnel, Supervisors, and Shop Floor Employees
Prerequisites:
- Lean Conversion Overview
- Lean Cultural Transformation
- Value Stream Mapping
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