TPM Workshop

1. day

Focus State of play, Survey

- Select area, topic 
- Kaizen team development, training 
- Tour and observation of the area 
- Identify sources of loss
- Design of measurement structure for OEE indicator
- Preparation of data collection plan
    OEE baseline data
    6 major losses 

2. day

Data collection, Analysis

- State of play survey, data collection
- Cycle time measurement, line balance and yield analysis
- Maintenance data scrap analysis
- Data validation
- Identification of sources of loss Quantification
- Pareto analysis
- Analysis of maintenance and troubleshooting processes

 

3-4. day

SEISO

Concept Design
 

- Base cleaning, machine and equipment overhaul (Seiso)
- Detection and analysis of sources of loss 
- Process and machine capability tests 
- Precise definition of development objectives
- Formulation of kaizen ideas
- Development and approval of development concept
- Approval of machinery and equipment development plans
- Approval of process improvement proposals

 

4-5 day

SEITON

Introduction, Trial run

- Restructuring, introduction of measures
- Modification of machinery, equipment, layout
- Improvement of machinery, equipment 
- Training 
- Review of maintenance and cleaning plans, instructions and checklists
- Definition of self-directed maintenance tasks
- Continuation of 5S (Seiton)
- Measurement, refinement

 

6. day

SEIKETSU

Efficiency-measurement, Closure

- Efficiency measurement, back-testing 
- OEE calculation
- Evaluation of results
- Corrective actions launched as necessary 
- Documentation of maintenance and changeover checklist standards
- Developing standardised work
- One-stop training 
- Final presentation
- Closing of the workshop