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EIEIO / AUTOMATION & EMERGING TECHNOLOGY

TPM – (II, AM, PM training) for Managers & Engineers

Course outline

2 days
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Duration

2 days

Objectives

This training intends to give a clear details of AM, II and PM activities so that the respective managers can set an appropriate action plan to support the top management TPM directions to achieve desirable results. Workshop will be included so that each Head of Department will derive the own business direction to support the company’s TPM vision to drive towards business successes.

Contents

Module A Introduction to TPM (Total Productive Maintenance).

Concept & Culture of TPM

Contents:

  • History and origin of TPM.
  • Differences between PM (Preventive Maintenance) & TPM.
  • TPM Definition.
  • Concept & Culture for TPM.
  • Current Business Development and Challenges.
  • Company-wide Implementation of TPM, Roles and responsibilities of each category of employees.
  • Concepts of JIT & TPM and their linkages.
  • Eight Pillars of TPM (Introduction)
  • Why we need to implement TPM activities?
  • Steps for TPM Implementation.
  • Company direction for TPM Activities
  • TPM Master Plan.
  • TPM steering committee & review process.

# Workshop : Develop your department activities to support company’s TPM direction.

  • Effective Measurement System for TPM.
  • One Point Lesson (OPL)
  • Activity Board Set Up.
  • Kaizen activities (Technical & General)
  • Management Indices such as Down Time, MTTR, MTBF, MTBA, Multiplexing Ratio, Direct Labour Productivity, Machine Productivity indices etc.
  • Matrix for measurement indices.

# Workshop : Set up your company’s TPM Target and Improvement plan with relevant measurement indices.

Module B. Concepts of Production Efficiency & Individual Improvement (Kobetsu Kaizen).

Contents :

  • What is production efficiency?
  • Loss in production. - 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.
  • Loss Matrix Analysis application
  • Comparison of Chronic Losses and Sporadic Losses.
  • Characteristics of Chronic Losses and Sporadic Losses.
  • Implication and effect of Chronic and Sporadic Losses.
  • Overview of PM (Phenomena Mechanism) Analysis
  • Concept of improvement.
  • Basic concepts of improvement, Restoration and Minor defects.
  • Concept of ideal condition.
  • Establishing Individual Improvement Teams.
  • Application of Why-Why and PM Analysis.

# Workshop: Draft out an improvement project template and use it to initiate a project to work on.

  • Calculation of OEE (Overall Equipment Effectiveness).

# Exercise : Calculation of OEE using raw data in both the simple method and the more analytical method

to find the cause of problem.

  • Meantime Between Assistance and Touch Measurements.

# Calculation examples and its impact to Man to Machine ratio

Module C. Autonomous Maintenance (Jishu Hozen) -- 7 steps.

Contents:

  • What is Jishu Hozen (Autonomous Maintenance).
  • Implementing Jishu Hozen.
  • Implementation plan.
  • Seven Steps of Jishu Hozen (Autonomous Maintenance) Implementation and Practical points.
  • Step 1. Initial cleaning.
  • Step 2. Counter measure for source of problems and 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.
  • Forming Small Group Activities to perform Jishu Hozen.

Module D. Planned Maintenance Implementation.

Contents:

  • What is Planned Maintenance.
  • Implementing Planned Maintenance.
  • Roles of Maintenance personnel.
  • 7 Stages of Maintenance disciplines.

# Breakdown, Routine, Corrective, Preventive, Predictive, Productive and Total Productive Maintenance.

  • “Zero Breakdown” Maintenance Chart.
  • Results of Planned Maintenance and its measurement.
  • MTBF
  • Downtime.
  • R & M Cost.
  • MTTR.

Workshop: Establish the criteria for selecting areas to implement PM activities.

Who should Attend

All Head of Department, Managers driving to implement TPM and need to understand the activities in philosophy as well as setting correct implementation action items and measurement indices for TPM activities.

Training Methodology

The course will be conducted in Workshop manner with all managers involvement to set up implementation plan for TPM activities. Video, exercises and lecture will be given in this training session.

Programme scope, delivery arrangements and suitability are confirmed during enquiry.