Module one: The Basics
Introduction
History of TPM
Principal Characteristics of TPM
Types of Maintenance
The universal Maintenance Cycle
Module Two: why TPM?
TPM Targets
Benefits of TPM
Overall Equipment Effectiveness (OEE)
OEE exercise
Mean times calculations (MTBF & MTTR)
Pillars of TPM
Module Three: The base, 5S
Introduction
SEIRI – Sort-out
SEITON – Organize
SEISO – Shine the work place
SEIKETSU – Standardization
SHITSUKE – Self Discipline
Keys to Success
Module 4: Pillar 1, Autonomous Maintenance
Definition and History
Paradigm Shift
Reliability, Availability and Maintainability
Basic needed skills for operators and technicians.
Roles of Maintenance/ Engineering departments
Success factors in implementing AM
Module 5: Pillar 2, Kaizen
Definition and History
The big 6 Machine Losses
Kaizen Implementation
Module 6: Pillar 3, Planned Maintenance
Which Types of Maintenance are applicable?
Root Cause Analysis as a core for planned maintenance
Basic RCA methodologies
FMEA
Ishikawa Diagram
Fault Tree Analysis
Pareto Analysis
Sequence of Events
5 Whys
SW tools and Case studies
Basics of Planning and Scheduling
Module 7: Pillar 4, Quality Maintenance
Definition
Policy and Targets
Quality Control Vs Quality Assurance
Basics of SPC, Statistical Process Control
Module 8: Pillar 5: Office TPM
Definition
Policy and Targets
Benefits of Office TPM
Technical Writing in Office TPM
Module 9: Pillar 6, Training
Policy and Targets
Training phases
Training Needs Assessment
Development of Training Programs
Module 10: Pillar 7, Safety, Health and Environment
Policy and Targets
Procedures and Standards development
Module 11: TPM implementation
Difficulties in TPM implementation
Importance of Computerized Maintenance Management System, CMMS
Suggested Plan for TPM Implementation
Course conclusion and Discussion
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