TPM Best Practice Implementation

The workshop begins with an introduction to TPM combining theory, exercises and case studies examples.  That develops awareness of foundation TPM principles and techniques and how they work together to provide a route map to zero breakdowns and beyond.

Delegates then work in teams to apply those lessons to selected shop floor assets. Through this they learn how to systematically eliminate the causes of unplanned outages and develop practical tactics to deliver the full potential of the asset under review. 

Where appropriate, this can include the use of TPM Digital toolsets such as micro planning, skill matching, dynamic scheduling and digital twin OEE glide path management.

Practical activities are guided using a structured TPM workbook.  With the support of the course leader they use the mini projects to develop examples of each step.  That provides delegates with a set of tools that they can use to apply lessons learned to other assets after the course.

Delegates also use the practical examples generated to learn how to design their own TPM implementation programmes.  That includes how to set and apply team based coaching standards to engage and support the development of front line teams and team leaders.

Outputs include the creation of a practical longer term vision of what TPM can achieve, 12 month programme goals and 90 day TPM mobilisation plans.

Participants are provided with a blank electronic copy of the workbook so that they can use it to apply the lessons learned to equipment back in the workplace. Participants are also provided with electronic copies of general awareness presentation material that they can use to raise awareness of TPM principles and techniques.

Business leaders, TPM Champions and Facilitators and First Line Managers who want to improve the effectiveness of their operations.

The course is also of value to Project Managers who have responsibility for delivering company-wide improvement programmes or operational capital projects

Morning Day one,

Following an introduction to TPM basics, participants work in teams to identify potential improvement opportunities on live projects using TPM mapping and criticality assessment techniques.

This helps participants to understand how to structure an equipment review, how to assess current standards and working practices and how to use the power of a practical OEE (Overall Equipment Effectiveness) measure to assess the value of improvement potential, set realistic and achievable improvement targets and identify practical improvement tactics to deliver that potential.

Afternoon Day One and Day Two

Participants continue to work in teams on mini projects where they carry out a condition appraisal and develop best practices for Asset Care, Planned Maintenance and Correct Operation.

They also gain an understanding of how these activities can deliver the challenging but achievable TPM goal of zero breakdowns. From this the programme progresses to the use of Focussed Improvement as a trigger for innovation and problem prevention.

During these activities teams are guided through the selection and application of relevant focussed improvement tools covering problem observation, analysis and solution development.

This includes

• the development of  Workplace Organisation, and Visual Management standards to aid standardisation, skill development and problem precention. 
• 5 Why and stoppage analysis routines to support progress towards zero breakdowns. 
• P-M Analysis to support progress towards process optimisation and zero defect goals. 

Day three

Participants feedback their respective project improvements and action plans to each other. In this way, participants gain a first-hand insight into the application of TPM toolset for up to 3 pieces of equipment.
The final session during day 3 covers the TPM master plan milestones, behavioural benchmarks and underpinning TPM systems.

During this session participants are guided through the completion of a TPM audit to assess the status of their organisation. This helps them to identify areas of good practice and priorities for action. There will also be plenty of opportunity to discuss specific implementation issues and develop personal action plans to implement the lessons learned back at the workplace

Workshop Leader - Dennis McCarthy

Author of books on TPM, Lean TPM and Early Equipment Management, Dennis' career includes positions in both general management and consultancy. Described by one senior international manager as a true "Sensei of Change" he has guided continuous improvement programmes ranging in size from small single site applications to company-wide multi-site transformation programmes. This has included support for well-respected and award winning companies such as 3M, Ford, General Motors, GE, IKEA, Heineken and Johnson Matthey across Europe, India, USA, China and Japan.