Example Seminar Outline

An example of one of International TPM Institute´s TPM Consulting Seminars, "Successfully Installing a Customized TPM Program in Your Plant."

I. Meeting the Manufacturing Challenge

  • Global Competition (even within your own company)
  • The Quality Challenge
  • Just In Time (JIT)
  • Cycle Time Reduction
  • Set-up Reduction (SMED)
  • Cost Reduction (Maintenance and Operations)
  • Capacity Expansion
  • Other (Your) Issues
  • The TPM Solution

II. Equipment, the FOCUS of TPM

  • Total Productive Equipment Management
  • Asset Utilization (ROA)
  • The Three Phases of Equipment Management
  • Lowering Life Cycle Costs (LCC)
  • Getting The Best from Your New Machines
  • TPM Goals, the Three Zeros
  • The Elements of TPEM ™
  • The TPM Organization (Line and Staff)
III. The Power of TPM

  • Eliminating Equipment Downtime, Idling and Minor Stoppages
  • Reducing Product Defects
  • Productivity Improvement
  • Controlling Maintenance Costs
  • Employee Participation, Teamwork
  • Return On Investment (ROI)

IV. Measuring Your True Equipment Productivity

  • Defining Equipment Productivity
  • How to Identify and Measure Equipment Losses
  • Calculating Equipment Effectiveness
  • Applying the Formulas (TEEP, OEE and NEE)
  • OEE Goals: What should you expect from your Equipment?
  • Setting Priorities for Your TPM Installation  

V. Customizing Your TPM Installation

  • Developing a TPM Strategy for Your Plant
  • The Three Components of TPEM ™
  • Autonomous Maintenance with a Difference
  • An Ounce of Prevention is Not Enough
  • Improving Your Equipment
  • TPM Installation Strategy (Priorities and Sequence) 

VI. How Much Autonomous Maintenance Do You Need?

  • Custom-Made Autonomous Maintenance
  • Recognizing Limitations
  • Training–The Key to TPM-AM
  • The Cost of TPM-AM
  • Certification of Operators
  • The “My Machine” Concept 

VII. How to Design and Install an Effective PM Program

  • Types of Preventive Maintenance (PM)
  • PM Strategy, Two Approaches
  • An Effective 10 Step PM System
  • The Secrets of Successful PM (TPM or not)
  • Operator-Based PM within TPM
  • Computer Friendly

VIII. Improving Equipment Through Problem Solving Techniques

  • CATS (Continuous Improvement Action Teams)
  • Feed the CATS (Four Sources of Input)
  • The CATS Meetings
  • Analyzing Equipment Problems (Four Techniques)
  • Reaction of Operators

IX. How to Organize and Execute the Feasibility Study

  • Contents of a TPM Feasibility Study (Seven Tasks)
  • Organization of the Feasibility Study
  • Execution of the Feasibility Study; Schedule
  • Feasibility Study Report and Presentation to Management

X. The TPM Installation

  • Phase I: The 10 Step Installation Planning and Preparation
  • Phase II: The Pilot Installation (and Schedule)
  • Forming Teams
  • Installing TPM-EM (Equipment Management/Improvement)
  • Installing TPM-PM (Preventive/Predictive Maintenance)
  • Installing TPM-AM (Autonomous Maintenance)
  • Setting Priorities for Your TPM Installation
  • Operator Training within TPM
  • Adapting your Maintenance Management System (CMMS)
  • Measuring and Reporting Progress and TPM Results
  • Recognition, Reinforcement, Rewards and Celebration

XI. How to “Fast-Track” a TPM Installation

  • TPM “Blast-Off”
  • A Fast-Track Schedule Example
  • Ingredients for a Successful TPM Installation