Total-Productive-Maintenance (TPM) For Reliable and Just-In-Time Value delivery to Customer The context of conventional TPM is now evolving towards embracing Total aspects of business improvement. To that extent, it may be appropriate to look at it as Total-Productivity-Management to become a leaner company. Expected Outcome: Upon completion of the Awareness program, participants will be able to: 1) Understand the Need, Principles and Tools of TPM, 2) Formulate TPM Deployment Strategy and Framework effectively so that TPM culture is evident, 3) Additionally upon completion of our 'Train-The-Trainers' program, the trainers shall be able to use TPM Tools to Eliminate Wastes in a chosen model workplace/equipment area. They shall be able to design road-map in order to improve the Overall Effectiveness and Efficiency (OEE) of Factory Operations including the Support Areas. For Various Posters such as here: Click here to see Table of Contents  For Whom: For anyone (from any functional area) who wants to function as a TPM change-agent/trainer (in manufacturing and service organization alike). However, the 1st awareness programme is primarily aimed at Top Management (Cross-Functional) Team who has authority to steer company-wide changes. The top team must learn-n-lead the process in order to make a successful cultural change up to grass-root level employees. What will the participants learn? – (Generic Contents*): 1. What is TPM? : An integrated part of Kaizen-Culture! 2. TPM goal: Aim Zero-Defect workplace & JIT response-to-customer 3. How to Enable TPM implementation (so as to create cultural change) 4. How to Pilot & Organize for TPM implementation in 10-Days 5. Eight Pillars & Management Commitment to Structured Pillar-approach 6. Role of Five-S in TPM in general and in SHE (Safety, Hygiene, and Environment) in particular 7. How to improve OEE (Overall Equipment Effectiveness)? 8. Focused Improvements: Kobetsu Kaizen (KK) in order to improve OEE. SMED to reduce Changeover/Setup times. 9. Phenomenon Mechanism analysis (PM Analysis) in order to solve chronic problems 
10. Autonomous maintenance (AM): Jishu Hozen (JH) 11. Quality Maintenance (QM): Hinshitsu-Hozen 12. Relationship of 5 Pillars of TPM and Quality Maintenance 13. Pokayoke for Quality Maintenance 14. Planned Maintenance (PM) Policies: Corrective, Renovative, Opportunity, Preventive, Predictive maintenance in order to control MTBF, MTTR, MTBT, etc. 15. Initial Flow Control (IFC): Facility Development and Early Equipment Engineering 16. Problem-free Engineering By Factory Management Area 17. Education & Training (ET): On-Job-Training, Behavioral Change (Nemawashi) & People Development 18. TPM in Office, Support Services, and Supply-chain clusters 19. TPM Audits, Improvements, Innovations, Benchmarking & Certification 20. What next? Evolve and Undertake IMPLEMENTATION Road-Map: A typical 4-stage Journey
* Key milestones may get reorganized & reworked for depth & for greater effectiveness depending upon audience/duration/objective of the course as in the table above. For effective results, please ask for diagnostic questions on the above points & reply before the course. Methodology (depending upon availability of time and teaching aids): Presentations, Case studies, Exercises, Action-oriented Gemba Kaizen depending upon the proximity of workplace, Group Discussions, Video clippings, etc. (The participant company may arrange Industrial Visits.) Course Material: The book ‘TPM in 10days' by Shyam Talawadekar Abbreviations: Mean-Time-Between-Failures, MTTR: Mean-Time-To-Repair, MTBT: Mean-Time-Between-Touches A few articles to learn from: An article on Effect of Education & Training | ||||||||||||||||||||||||||||||||||||||||
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