Course Overview
The Route Map to Zero Breakdowns and Beyond
This is a course designed to support those tasked with achieving the challenging but achievable TPM goal of zero breakdowns. Exercises include a structured gap analysis framework to identify strengths and barriers to Reliability. The assessment is then used to guide the development of bespoke action plans to deal with gaps and enhance existing good practices. That includes a section on the potential of cloud based digital technology to address gaps and pain points.
Often described as applied common sense, Total Productive Maintenance (TPM) is a proven approach to delivering high levels of operational reliability and effectiveness. Its success is due to the recognition that few of the problems which impact on reliability can be resolved by purely technical improvements.
At the heart of the TPM process are practical, cross functional team processes that systematically improve Overall Equipment Effectiveness as part of the daily routine. This provides local and senior leadership with the levers to engage production and engineering personnel with a shared improvement agenda.
To support that, the course includes the use of a TPM review framework to identify current status and set out a practical leadership agenda to guide progress towards first stable and then optimised operational performance. That includes tactics to lock in the gains and redirect specialist and management time to make better use of their knowledge and experience.
These are all reasons why TPM is more accurately referred to as Total Productive Manufacturing.
Why attend this workshop?
Why attend?
Participants will:
Learn how to stabilise and improve effectiveness as part of the daily management routine
Understand TPM principles and how to apply them
Know how to engage front line teams with systematic improvement of asset effectiveness
Be able to develop a practical programme to deliver zero breakdowns and systematic improvement in operational effectiveness.
Who should attend?
The workshop content is designed to provide practical support for those meeting the challenge of taming technology and ratcheting up performance that includes:
• Business Sponsors
• Team Leaders
• Production and Maintenance specialists
• Change agents
Workshop Agenda
DAY 1
Introduction
TPM principles and techniques
Daily Management of performance and improvement
- OEE Simulation
- Defining the OEE improvement glide path
Reliability Gap Analysis
- The reliability road map
- The foundations for zero breakdowns
- The cross functional agenda
- Building capability
- Locking in the gains
- Setting the leadership agenda
Digital CI
o The advanced technology landscape
o Where the gains come from
o Matching digital solutions to gaps and pain points.
DAY 2
Normal Conditions and Downtime Prevention
- Asset care and Operations Best Practice
- Standardisation
- Leader Standard Work
- Compliance, feedback and systemisation
Taming Technology
- Learning from sporadic losses
- Countermeasures to common problems
- Designing trouble shooting algorithms
Ratcheting up performance
- P-M analysis
- Targeting waste and hidden losses
- Human Factors
- Job design and method development
- Learning pathways and learning plans
DAY 3
TPM programme Leadership
- Change Master Plan
- Gap analysis/TPM Audit
Implementation milestones (Pilot/roll out)
- The improvement leader network
- Securing engagement
- Raising Performance/Standards.
Action plan development
- Developing a practical TPM vision the team can get behind
- Defining realistic and achievable 12 month planned outcomes
- Developing the 90 day workplace learning cycle.
Review of the Workshop
Workshop Leader
The workshop will be led by Dennis McCarthy.
Dennis has supported Total Productive Maintenance, Lean Thinking and Continuous improvement programmes ranging in size from small single site applications to company-wide multi-site transformation programmes in Europe, USA, India, China and Australia.
