TPM Training 

1. What is TPM?
History, developers, development of maintenance idea and TPM.
From improving production effectiveness to strategy of company development – various TPM levels
TPM and Lean Manufacturing
2.What can you expect from TPM
Set objectives
Examples of achievements
3.TPM bases
Short description of 8 pillars.
Roles in TPM:
new roles for a mechanic and an operator
4. Strategy for implementing TPM
Planning (objectives, methods, benchmarking, resources, structure, training for management) Awareness (appointing leaders, training courses for them, preliminary information for the workers, determining the pilot area and schedule) Determining indicators, methods of monitoring and communication (boards), motivation.
Pilot implementation
Testing the implementation effectiveness and its verification
Complete implementation
Extension and improvement
5. 6 types of waste according to TPM
breakdowns
equipment changeover
low quality
start-up reduced speed
minor stoppages.
6. TPM indicators
How to select indicators?
Global productivity: simplified and complete OEE. OEE calculations – exercise
Maintenance indicators: MTTR, MTBF, MDL
Operational Availability (OA)
Practical measurements of indicators – sheets, software supporting indicators
Indicators visualization
7. Autonomous Maintenance.
Preparation (start-up photo; preparing the team, objective, indicators, visualization, etc.)
Cleaning as control measure Elimination of anomalies sources
Defining preliminary standards
General inspection
Standardization
Self-maintenance
Exercise:
Preparing the plan for autonomous maintenance for the exemplary equipment (mincer, food processor, skis, rollerblades)
8. Improvement Orientation
Definitions
Kaizen
Improving creativity
Communication and problems solving
Teamwork
9.Special Maintenance
repairing breakdowns – prevention – improvement:
Maintenance way
specification of preventive measures for Maintenance
implementing prevention into Maintenance System
training and development of workers
documentation on actions
Exercise: Kaizen mini-training conducted on a selected production machine, or an exemplary division of tasks: operator – maintenance on the example from the production area.

participants: middle and high management, Maintenance Department, experts. The programme is modified depending on the type of participants. For example, the management will lean more about bases and strategies of implementation, and Maintenance Department will learn more about technical details.

duration: 2 days

type of training: closed. If you are interested in open training courses, click here .

programme objective: to prepare people to act as leaders of TPM system in their companies. Also other workers having contact with TPM system can take part in the training.

trainers: course is conducted by people having practice in manufacturing companies (usually automotive ones). They have been involved in implementing TPM in their companies, and now they can share their experience. This training is co-conducted by a psychologist, who helps in dealing with reluctance to changes and interpersonal conflicts which arise during its implementation.

methodology: theoretical introductory part, exercises, discussions, solution of problems, discussion of case studies. A part of TPM training can be organized on the spot – in the implementation area.

content of training materials: manual prepared individually for every customer, photos taken before and after implementing individual steps.

certificates: Basic TPM issued by Polish Productivity Center.