Total Productive Maintenance | TPM
Achieving a Total Productive Maintenance (TPM) certification demonstrates a commitment to optimizing operational efficiency and minimizing downtime. This certification equips professionals with the skills to implement proactive maintenance strategies, fostering a culture of continuous improvement. By mastering TPM principles, individuals contribute to enhanced equipment reliability and overall productivity. In today’s competitive landscape, a TPM certification sets a benchmark for excellence, showcasing an individual’s proficiency in maintaining peak operational performance.
Course Objective
The TPM certification course aims to equip participants with comprehensive knowledge and practical skills in Total Productive Maintenance (TPM). Focused on enhancing organizational efficiency, the course covers key objectives such as understanding the principles of TPM, implementing preventive maintenance strategies, and fostering a culture of continuous improvement.
With a focus on real-world applications, this TPM certification course empowers professionals to lead successful TPM initiatives in their workplaces, ensuring sustained operational excellence and positioning them as adept practitioners in the field.
Who Should Attend
- Maintenance Managers and Supervisors
- Production Managers
- Leadership and Decision-Makers
- Operations Managers
- Frontline Operators
- OEE Managers
- Quality Assurance and Control Personnel
Benefits of Attending
Participating in a Total Productive Maintenance (TPM) program offers numerous benefits:
1. Enhanced Equipment Reliability: Implementing TPM practices leads to increased machinery uptime and reduced breakdowns, resulting in improved overall equipment reliability.
2. Increased Productivity: TPM emphasizes proactive maintenance, minimizing unplanned downtime and optimizing production processes, contributing to heightened productivity levels.
3. Cost Reduction: By preventing breakdowns and addressing issues promptly, TPM helps in reducing maintenance costs and avoiding expensive repairs, leading to overall cost savings.
4. Improved Product Quality: TPM’s focus on preventing defects and maintaining equipment ensures a higher standard of product quality.
5. Employee Engagement: Involving employees in the TPM process fosters a sense of ownership and responsibility, leading to increased engagement and a positive work culture.
6. Enhanced Safety: Regular maintenance and equipment checks in TPM contribute to a safer working environment, reducing the risk of accidents and injuries.
7. Optimized Overall Equipment Effectiveness (OEE): TPM aims to maximize OEE by addressing factors that impact availability, performance, and quality, leading to improved operational efficiency.
8. Cultural Shift Towards Continuous Improvement: TPM encourages a culture of continuous improvement, where employees actively contribute to identifying and implementing better practices, fostering innovation and efficiency.
9. Extended Equipment Lifespan: Proper maintenance and care under TPM result in prolonged equipment life, delaying the need for costly replacements.
10. Competitive Advantage: Organizations implementing TPM gain a competitive edge by ensuring efficient operations, high-quality products, and a commitment to continuous improvement in a dynamic business environment.
TPM emphasizes proactive maintenance, minimizing unplanned downtime and optimizing production processes, contributing to heightened productivity levels.
Training Outline
1. Overview of TPM
– Definition of TPM
– History & Impact of TPM
– Goals of TPM
– Contribution of Maintenance cost in total cos
2. Understand various Equipment Losses
– Breakdown Losses
– Setup & Adjustment Losses
– Idling & minor Stoppage
– Startup Restart Losses
– Other Related Losses
3. Activities before TPM
– Developing the maintenance Organization
– Equipment Information Management
– Inventory Information Management
– Organizational Assessment
4. The 8 Pillars of TPM
– Autonomous Maintenance
–Planned Maintenance
– Safety, Health
– TPM in Administration
5. Developing TPM Implementation Plan
– Ten step TPM Implementation plan ( Developing the long range plan
– Selling the programme, Ensuring Equipment reliabilities
– Maintenance Inventory Control
– Maintenance Automation
6. Understanding of OE
– Measurements/Accuracy/Reasons Why
– How to turn OEE data into information
– Average OEE’s vs. World Class OEE’s – myths and realities
7. Maintenance Information System
– Basic of CMMS
– Why Computerize
– What makes a good CMMS
– How to select good Maintenance Software ? steps to successful implementation
8. Improving Maintenance Efficiency and Effectiveness
– Examining craft technician
– Planning maintenance activities
– Scheduling Flow
9. Understand concept of Total Economic Maintenance
– Cost-Benefit Decision
– Calculation of maintenance cost
– Lost performance Calculation
– True total cost Calculation
– Critical Spare Analysis
10. Effect of Visual Controls on Total Productive Maintenance
– 5S Workplace Organization and Impact on TPM (the surprising root cause of 40% of equipment breakdowns)
– Continuos Maintenance Improvement Visual Management System
– Cultural Considerations and Team Working
Training Deliverables
GROUP EXERCISE
PAIR EXERCISE
CASE STUDIES
INDIVIDUAL EXERCISE
PROJECT SELECTION
POWER POINT
VIDEO DEMO
RELEVENT TESTS
SITE VISITS
ROLE PLAYS
Feedback From Past Participants
The TPM training significantly enhanced our understanding of proactive maintenance strategies, leading to a remarkable boost in operational efficiency.
This session comes highly recommended for all managers seeking to cultivate a more structured approach to quality development.
Our ability to prevent breakdowns and address issues promptly has led to a noticeable improvement in overall equipment performance and a positive impact on our bottom line.