TPM master

1.        day

TPM SYSTEM

-    TPM conditions
-    TPM basics: 5S – Kaizen, data collection

Lean Management – TPM basics

Gemba Kaizen

-    5 GEN, Gemba Kaizen

PDCA - SDCA cycle

-    Maintenance and continuous improvement
-    Based on facts leadership
-    Measurement, data collection
-    Determine targets and requirements
-    Function of standards 
-    Steps of standardization
-    Elements of standardized work

5S Standards method

-    5S steps, introduction
-    Self-motivated maintenance

Visual management

-    Information structures, control
-    Examples of visual management  

Involving employees

-    Employee in the focus principle 

Catapult game – PDCA

2.        day

TPM SYSTEM

-    Maintenance approaches
-    TPM concept and structure
-    5 construction elements of TPM (pillars) 
-    TPM system 
-    Life cycle and management of the equipment

RELIABILITY THEORY BASICS

-    Statistical basics
-    Process and machine capability studies (Cp, Cpk, Cm, Cmk)
-    Reliability analysis of production lines
-    MTBF, MTTR indicators

EQUIPMENT IMPROVEMENT, LIFETIME IMPROVEMENT

-    Examination
-    Constructional improvement

Loss identification, measurement

-    Based on facts leadership
-    Registration - Correction - Prevention
-    6 large losses related machines

OEE indicator and calculation

-    Machine failures, Micro down times 
-    Setting, Change over processes
-    Quality loss, waste
-    Reduced speed, waiting/standing 
-    Start-up losses

SMED

-    Change over matrix
-    Change over process
-    Spaghetti diagram, Standard work combination sheet
-    SMED preparation 
-    Identifying external-internal times
-    Reduce change over time

3.        day

PROBLEM SOLVING

-    Tools of problem solving
-    7 QC tools
-    Selection and implementation of the solution
-    Kaizen diary, action plan
-    Standardization, maintaining results

Problem solving in team

-    Brain storming, Affinity diagram
-    Check list in 7 steps

0 DEFECT CONCEPTION

-    Defect alert, Alert system, Andon
-    Defect recognition
-    Defect elimination, correction
-    Defect method
-    FMEA method
-    JIDOKA, POKA-YOKE 

KAIZEN Story Board

-    Presentation of the KAIZEN results

4.    day

MAINTENANCE MANAGEMENT 

-    ABC analysis, identification of critical machines
-    Maintenance approaches
-    Maintenance process and tasks
-    Machinery maintenance - diagnostics
-    Recognizing defects and sources
-    Defect alert card usage
-    Machine status inquiries, machine capability test
-    Planned maintenance system including preventive maintenance
-    Preventive maintenance program

Full participation – involving employees

-    Connection of TPM, 5S and KAIZEN

Self-motivated maintenance management

-    Machine hosts, autonomous maintenance
-    Phases of the self-motivated maintenance management 
-    OPL – One-point lessons
-    Maintenance, cleaning, control plans, work instructions and check lists 

TPM ACTIVITY DISPLAY

-    Defect card usage
-    TPM board

PILOT PROJEKT
TPM, KAIZEN action implemented at the participant’s workplace

-    Presentation structure
-    Presentation techniques

Exam:
- Presentation of the individual KAIZEN action
- Written exam