Lean maintenance - TPM

1.        day

Lean Management System

Lean Management Philosophy
-    The history of the Lean Management and the TPS 
-    Lean production, Lean Office
-    Value-added approach 
-    Lean principle (5 principles)
Lean Management Construction elements
-    Pull system, JIT 
-    JIDOKA, 0 defect concept 
-    KAIZEN 
-    Involving employees 
-    Stable Operation
KAIZEN philosophy and approach 
-    Connection of KAIZEN and Lean 
-    Features of KAIZEN 
-    Four principles of KAIZEN 
-    Examples of the  KAIZEN implementation 
Simulation game - Lean production versus traditional production

2.        day

5S – Lean Management basics

Gemba Kaizen
-    5 GEN, Gemba Kaizen approach
PDCA – SDCA cycle
-    Maintenance and continuous improvement
-    Based on facts leadership
-    Measurement, data collection
-    Determine targets and requirements
Standards
-    Function of standards 
-    Steps of standardization
-    Elements of standardized work
5S method 
-    5S steps, introduction 
-    The implementation of 5S method 
-    Viewpoints of the implementation of 5S 
-    Scheduling the implementation of 5S 
-    Possibilities of maintenance, 5S audit
Visual management
-    Information structures, control
-    Examples of visual management  
Catapult game – PDCA

3.        day

KAIZEN – Problem solving

-    Problem solving in 7 steps, Kaizen steps
Problem exploration’s tools
-    Defining problem (Tregoe)
-    Identify KAIZEN possibilities 
o    PQCDSM check list 
o    4M method
o    5W 1H method
o    3 MU method
-    5 WHY method
Task: KAIZEN practice
Further analysis tools
-    Flow charts, Value Stream Mapping  
-    Performance measurement, Benchmarking
-    5W 1H method 
-    Spaghetti chart, cycle time chart 
-    -  Standard work combination sheet
7 MUDA – loss exploration 

4.        day

Problem solving

-    Problem solving tools
7QC tool
-    before KAIZEN, after KAIZEN 
-    Kaizen diary, action plan 
Collective problem solving
-    Brain storming, Affinity diagram
-    Check list in 7 steps 
Loss reduction
-    Cycle time balancing
-    Standing time reduction
-    Material flow optimization
0 defect concept
-    FMEA, good quality first
-    JIDOKA, POKA-YOKE
Kaizen Story Board
-    Presentation of the KAIZEN results

5.        day

TPM system

-    TPM concept and structure 
-    8 principles (columns) of TPM  
-    TPM system 
-    Basics of Reliability theory
Loss reduction related machines 
-    6 large losses related machines
-    Measurement of losses related machines (OEE)
-    Ranking problems based on indicators
Increase machine occupancy
-    Reducing failures
-    Maintenance approaches
Maintenance management
-    Self-motivated maintenance management 
-    Planned maintenance system including preventive maintenance
-    Preventive maintenance program
-    TPM activity display 
SMED 
-    Change over process
-    SMED preparation 
-    Identifying external-internal times
-    Reduce change over time

Exam
-    presentation of the individual KAIZEN action 
-    written exam