Total Productive Maintenance

Day One

• Define and discuss TPM.
  • Understanding what is meant by TPM
  • Understand why it needs to supported by all employees
  • How it will be carried by all employees?
  • How to implement on a company wide basis?
  • All equipment and functions included
  • Maximizing efficiency and effectiveness
  • Compare TPM to other maintenance concepts.
  • What are the similarities?
  • What separates TPM from all other concepts?
  • Implementing proactive versus reactive solutions
  • Benefit from increased productivity
  • Describe the implementation of TPM
  • Introduction by Senior Management
  • Supported by Senior Management
  • Encouraged by maintenance and operational staff
  • Continuous monitoring and follow up of program
  • Measuring results at certain intervals
  • Why TPM is required by all employees of the organization
  • To increase productivity and bottom line
  • To increase the quality of the product
  • Increases reputation of the organization
  • Increase motivation levels of the employees
  • How to increase TPM efficiency and effectiveness
  • Value the employees
  • Respect all ideas and recommendations
  • Recognize employees for job well done
  • Understanding the goals and objectives of TPM
  • Provide a detailed introduction program to all employees
  • Check for understanding
  • Check for barriers that might prevent success
  • Lead by example and not by objectives alone
• How to maximize equipment performance?
  • Employees properly trained to maximize equipment performance
  • Ensure availability
  • Ensure performance efficiency
  • Make every effort to reduce equipment down time
• Difference between “Zero Defects and Zero Breakdowns”
  • Understand the difference
  • Avoid equipment degradation
  • Eliminating defects and breakdowns, increases quality and output
• Appropriate problem solving exercises such as:
  • Brainstorming
  • Creative Solutions
  • Using the “Four” Step problem solving method
  • Force Field Analysis and other forms of problem solving

Day Two

• Understanding how PQS relates to TQM and the final product
  • To get an understanding of PQS
  • Integrating PQS or similar program with TPM
  • PQS leads to employee qualification on specific positions
  • PQS qualified employees increase product output
• Describe preventive maintenance and understand the need of a Preventive Maintenance System (PMS) within the organization
  • Understand the function of PMS
  • PMS reduces equipment failure and breakdowns
  • Increase TPM efficiency and quality of the product
  • Becomes a systemic approach in the organization
  • Reduces waste of resources and increase productivity
• Describe breakdown maintenance and some of the causes
  • Poor planning and Intentional sabotage
  • Non-existent equipment inspection procedures
  • No preventive maintenance schedules
  • Poor training or unqualified employees
• How to reduce Reactive Maintenance (as it occurs)
  • Proper training of employees
  • Pre-planning of maintenance activities
  • Understanding maintenance problems
  • Implement a scheduled maintenance program
• Combining PMS and Maintenance Planning to reduce breakdowns
  • Employee’s qualifications and equipment experience
  • Who will perform the designated task?
  • Refinement and implementing existing maintenance steps
•  Appropriate problem solving exercises such as:
  • Brainstorming
  • Creative Solutions
  • Using the “Four” Step problem solving method
• Force Field Analysis and other forms of problem solving

Day Three

• Describe the ideal TPM implementation methods
  • Organization focused on Vision and Mission
  • Utilizing employees to full potential
  • Understanding the limitations of the individual
  • Providing a positive working environment
  • Being a proactive organization at all times
  • All employees are in agreement with the program
• Describe the practical limitations to an ideal TPM implementation
  • Employee Skills, knowledge, and experience
  • Tools and equipment
  • Increase productivity, quality, and safety
• Describe the benefits of a properly implemented TPM program
  • Motivated employees
  • Increased productivity and output
  • Increased quality of product
  • Reduction of loss time and waste of resources
  • Increased safety and reduction of lost man hours
• Describe the need to communicate between work groups
  • Eliminates internal problems and conflicts
  • Increases motivation and cooperation
  • Increases the efficiency and effectiveness of team
  • Avoids paralysis by analysis
  • Meeting schedules and deadlines of productivity
• How to improve training and reduce qualification periods using PQS
  • Understand that training is not a “Fit All” solution
  • Understand the needs of the organization and the individual
  • Long and more training does not mean it is better
  • Focus on the needs of the individual increases for better results
  • Using motivated and experienced staffs who want to train others
  • Understand that not all employees learn at the same pace
• How to improve safety practices and implement safety methods like “Fresh Eye”
  • Assisting safety teams to improve safety program
  • Military program, but not utilized in any industry
  • Implementing program requires Senior Management involvement
  • Getting all hands involved and expecting collaboration
• Appropriate problem solving exercises such as:
  • Brainstorming
  • Creative Solutions
  • Using the “Four” Step problem solving method
  • Force Field Analysis and other forms of problem solving