Achieving Total Process Reliability Through TPM Classes

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Detailed Overview/Outline

Here at last is a proven and successful process for involving maintenance in organizational improvement. Total Productive Maintenance (TPM) is a rapidly growing process that many companies are seeing as the major quality movement in the maintenance field. It is an effective process that has operators and maintenance craftsmen working together as a team to reduce waste, minimize downtime, improve product quality, and improve equipment effectiveness. This is accomplished by focusing on those things that prevent a machine from running at optimal condition and by sharing responsibility of equipment upkeep.

TPM builds on the concepts of “just-in-time”, “zero defect/downtime” and “design to life-cycle (LCC)” maintenance, and has expanded from the auto industry to pharmaceutical, paper, printing, cement, ceramics, food, semiconductor, petrochemical, and oil industries, with significant development in the process industries.

A recent study of over 100 factories that have converted to TPM in the last few years (65 of these since 1983) has shown: Worker productivity increased by 60%, Accidental breakdowns reduced to nearly zero (1%) and Overall productivity increased by 85%.

WHAT IS TPM: THREE BASIC IDEAS

• Optimize Equipment Effectiveness
• Autonomous Operator Maintenance
• Company-Led Small Group Activities

All three TPM concepts involve the Total Organization - this is definitely a “high-employee involvement” concept. Yet, as you will learn, TPM does not lead to conformity and boredom; rather to creative group effort, individual effort and responsibility, and lively problem solving techniques. TPM concepts involve commitment to long range planning and patient resolve, especially on the part of management; typically TPM is initiated “top-down”, but only implemented successfully “bottom-up”. Participation and “consensus-building” takes time: you should be prepared for three years from planning stage to stabilization.

WHY TPM?

TPM is profitable for the company—Automated factories are expensive - the consequences of breakdown or malfunction are more immediate and costly than in traditional plants - high machine utilization is critical; productivity depends on keeping the equipment working at peak level, all the time.

TPM is appropriate for the workers—Integrated plants require integrated workers: highly skilled, flexible, and committed - higher levels of competence are consistent with management styles (high involvement, employee participation, self-managing teams, etc.) required for a global market.

TPM is World Class—because it prepares your plant to meet the challenge of a competitive global economy (not only the Pacific Rim, but now a united European Common Market). TPM concepts will:

• Improve Overall Plant Productivity
• (more efficient operations and resource utilization; elimination of unnecessary inventory)
• Improve Plant Throughput
• (quicker action/reaction leading to reduced downtime)
• Improve Product Quality (and Service)
• (better designs, better maintained machines produce better products; fewer shutdowns and startups produce less quality variations)
• Reduction of equipment failure by 20%-30% increases productivity by 40%-50%.

BENEFITS

A step-by-step blueprint to achieve zero breaksdowns, zero defects, and improved throughput by:

• Increasing operator involvement and ownership
• Improving Team problem solving
• Refining preventive and predictive maintenance activities
• Focusing on reliability and maintainability engineering
• Upgrading operator and maintenance skills

SPECIAL FEATURES

A step-by-step program for developing and implementing the Total Productive Maintenance concept geared to your specific situation.

• An objective approach, providing you the unique opportunity of bringing management, supervisors, and unions up to speed by attending the program together.
• Program leaders who have special expertise and broad experience in the maintenance profession. Our seminar leaders bring more than 60 years of actual in-plant maintenance management experience; they know what works (and what doesn't). A 450+ page “TPM Implementation Manual”, full of charts, graphs, check lists, articles, plans, and procedures - an excellent guide to implementing TPM.
• Review a case study article of successful TPM implementation

Instructor(s):
Preston Ingalls, Greg Folts

Instructor Background:
Preston Ingalls is an experienced engineer, training specialist, and performance development consultant. Over the last twenty-six years, he has analyzed, designed and implemented numerous organizational improvement projects for companies both large and small. He is an authority in high-involvement, high employee participation problem solving approaches and has set up and served as a facilitator for numerous programs.

Greg Folts. Mr. Folts is an experienced manager of continuous improvement having gained his knowledge first-hand directing improvement initiatives for an aerospace bearing supplier, MRC Bearings. These initiatives included responsibility for implementing TPM, 5S, lean production, setup reduction, Six Sigma and ACE initiatives in a 1000 employee, union factory.

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