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Lean Maintenance (Total Productive Maintenance) 1 Day Workshop

1 day
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Location: Dublin (Louis Fitzgerald Hotel)

TPM is often the first place to begin the journey towards Lean Transformation because it creates a manufacturing environment of stability, reliability, and capability.

Overview

Total Productive Maintenance (TPM) is often the first place to begin the journey towards Lean Transformation because it creates a manufacturing environment of stability, reliability, and capability. A stable infrastructure is a critical foundation that must be built before more tightly coupled Lean practices can be successfully introduced and more importantly sustained.

Participant Profile

This introductory course is designed for frontline employees, maintenance and production supervisors, and managers interested in deploying TPM.

Morning Session

  • The History and Evolution of Maintenance in the Context of Lean Management
  • The 5 Pillars of TPM (Continuous Improvement in OEE, Maintenance Asset Care, Operator Asset Care {Autonomous Maintenance}, Skills Development, and Early Equipment Management)
  • The TPM Model of:
    1. Measurement Cycle (Historical Analysis, OEE, 6 Losses)
    2.  Condition Cycle (Criticality Assessment, Condition Appraisal: Spot the Rot, Refurbishment Plan and Spares, Asset Care)
    3. Problem Prevention Cycle (Best Practice and Problem Prevention)
  • The 4 Core TPM Metrics for the Attainment of Flow

Afternoon Session

  • Current State Diagnostic Audit Exercise
  • FMEA to Mitigate the 80/20 Breakdown Risks and Exercise
  • Predictive Maintenance – Methods of Predicting Time between Equipment Failures
  • Cultural Considerations and Team Working
  • 5S Workplace Organisation and Impact on TPM (the surprising root cause of 40% of equipment breakdowns)
  • Quick Changeover and TPM
  • Continuous Maintenance Improvement Visual Management System
  • TPM Implementation Roadmap Exercise

The goals of TPM include:

  • Reducing unnecessary downtime due to breakdowns, minor stoppages, and quality problems
  • Enhanced maintenance and frontline employee engagement and collaboration
  • Systematically learning from equipment related problems so that root causes can be identified and addressed
  • Fostering productive dialogue between production managers, employees, and maintenance staff.

This one-day workshop will introduce key TPM concepts, root cause analysis and the strategies for a successful TPM pilot and wider journey

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