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Total Productive Maintenance (TPM) is a process to maximize the productivity of your equipment for its entire life and will extend the life of the equipment. TPM fosters an environment where improvement efforts in Safety, Quality, Delivery, Cost and Creativity are encouraged, through the participation of all employees. The goal of TPM is to maximize your Overall Equipment Effectiveness (OEE) and to reduce equipment downtime while improving quality and capacity.
Workshop Objectives
This workshop is designed to show that Total Productive Maintenance (TPM) goes far beyond traditional
maintenance boundaries to attack equipment-related waste, including: downtime, speed losses, defects, frequent adjustments, changeover, and breakdowns. Participants are provided a method to proactively maintain machines and equipment at their peak productivity. This group training exercise is designed to precede a TPM implementation, or Kaizen event.
• Understand TPM and its major components, including how to measure and increase overall equipment effectiveness and how TPM can help avoid interruptions to production
• Explain how the TPM process is integrated with other Lean tools to increase productivity
• Gather and analyze Overall Equipment Effectiveness (OEE) data to determine equipment constraints
• Identify the six major equipment-related losses and how to minimize them in order to increase OEE
• Learn how implementation of the TPM process fosters improvement efforts in safety, quality, delivery, cost, and creativity by all employees
Topics Covered
| • Defining Lean | • Analyzing the Major Losses |
| • Defining TPM | • Five Steps Towards Improvement |
| • Current vs. Future State | • TPM Implementation Process |
| • Overall Equipment Effectiveness | • TPM Case Studies |
| • Six Major Losses | • Keys to Success |
| • Documentation Tools | • Performance Impact and Benefits
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Kaizen Implementation Event
IMEC will facilitate a group of your employees through the Total Productive Maintenance process, implementing the techniques learned in the workshop. A more extensive Preventive Maintenance program must be developed and implemented, along with research into possible application of Predictive Maintenance techniques over time. These activities typically are addressed after the Kaizen event has been completed, as are abnormalities that cannot be immediately corrected. Therefore, the team will develop an action plan with assigned responsibilities and expected completion dates to insure that the necessary follow-up takes place.
Benefits of Total Productive Maintenance
TPM reduces equipment-related waste including: downtime, speed losses, defects, frequent adjustments, breakdowns, etc. Typical manufacturing operations have experienced improvements in the following areas in a relatively short period of time (6-12 months) through the implementation of TPM:
• Overall Equipment Effectiveness (capacity) improvement of 25-50%
• Quality improvement of 25-50%
• Maintenance expenditure reductions of 10-50%
• Percent Planned vs. Unplanned maintenance increase of 10-60%
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Asset Optimization Services |