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  4. Total Productive Maintenance Awareness

Why Total Productive Maintenance

Indian industries are poised for excellence and have begun building sustainable manufacturing excellence components into their manufacturing units. The Total Productive system (TPM) was initiated in Japan by JIPM (Japan Institute of Plant Maintenance) in 1971 based on the preventive maintenance measures developed in USA in the 50s, which then developed to productive maintenance and finally to Total Productive Maintenance. By adopting to the system, organization can make their equipments as well as the whole manufacturing unit into an effective one.

Ineffective utilisation of machines, as a whole creates financial burden to the organization towards investment in those equipments and tools. As a consequence the skills of the operators and supervisors also go waste. The time and energy of the managers will be spent on monitoring the personnel and taking care of the maintenance of equipments makes the organization unproductive. In order to achieve the effectiveness and increasing the efficiency of operatives, all the people concerned should be made aware of the TPM system and philosophy behind it.

As a result TPM will build up a continuous improvement culture and system to achieve zero accident, zero defect, zero breakdown and zero waste by involving all functions and all workforce using a series of TPM tools and developing workforce skills. The unique advantage of TPM system for any manufacturing industry is that, it has combination of both American and Japanese system enabling easy adoption.

TPM certification procedure adopted by the Japan Institute of Plant Maintenance has stringent norms, desirably the manufacturing units should initiate their TPM system with basic awareness at all levels of the organization.


Course Objectives

  • To understand TPM premises, pillars and the tools & techniques,
  • To understand the concepts of TPM pillars
  • To know the method of developing the foundation for TPM pillars
  • To know the system of building the steps in each pillar
  • To understand roles & responsibilities of employees at various levels in building sustainable TPM system
  • To understand the methods to develop a monitoring system based on the TPM Master Plan

Course Features

The course is designed to create awareness of the importance of the TPM system in a manufacturing unit and also to provide basic understanding of the roles of employees at various levels. With basic knowledge of the manufacturing process and machine/equipment functions, any person can acquire the knowledge of TPM system and its components. Knowledge of Manufacturing Process and use of machine/equipment maintenance system will be desirable.

Who should attend ?

  • Production and Maintenance Engineers
  • Heads of Process
  • Heads of the manufacturing units
  • Quality and Production and Process Control Managers
  • Production Supervisors
  • Industrial Engineers
  • Students aspiring for Production or manufacturing jobs with at-least one year hands-on experience in any manufacturing industry

Course Contents

  • Introduction and TPM history
  • TPM Philosophy
    • TPM Organization and Pillar Structure
    • Purpose and outcome of pillars
    • Pre-TPM conditions checklist
  • Pillar Structure
    • Autonomous Maintenance and Steps of autonomous maintenance
    • Individual Improvement and steps of individual improvement
    • Planned Maintenance
      • MTBF
      • MTTR
      • Key indicators Briefing
    • 5S system – Foundation for TPM Pillars
  • Pillar Structure (Continued)
    • Quality Maintenance
    • Development Management through Standard Work and One Point Lessons
    • Safety, Health and Environment
      • Zero accident
      • Zero Health damage
      • Zero fires introduction
    • Office TPM
  • Sixteen Major Losses
  • OEE Measures and calculation
  • JIPM Certification norms and TPM Master Plan
  • End of course

Certificate

Certificate of attendance shall be issued to all the delegates attending entire duration of the training course.

Duration

2 Days

           

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