Save the date June 18-21 The TPM Experience Baltimore, MD

Total Productive Maintenance (TPM)
Training

The Productivity Inc. team has the ability and real-time experience to deliver the technical and social aspects of TPM tailored to your environment. Our training process has a foundation of standard work and job instruction prescribing the use of reliable, ideal methods. All of Productivity’s training programs are supported by a variety of team and small group learning activities, such as, exercises, simulations, and business case studies challenging the participants to experiment and explore the scientific methods embedded in Plan, Do, Check, Act.

• 5S/Visual Workplace

  Learn the principles and techniques needed to apply 5S and establish visual management systems to improve workplace communication and adherence to standards. This training session will teach you how to share information about daily production problems, abnormalities, waste, and unsafe conditions through visual display and controls so that everyone understands at a glance what is going on in the workplace.
  
  

• Autonomous Maintenance

  Arguably the backbone of your equipment maintenance program, Autonomous Maintenance, when properly implemented, can eliminate the causes of 40-60% of unplanned downtime. In this kaizen style training event, we will guide your work teams through the seven steps of autonomous maintenance implementation, how to transform the relationship between operators and maintenance, and how to implement operator-based maintenance activities that contribute to overall equipment effectiveness. This event is comprised of classroom teaching and shop floor hands-on application.
  
  

• Early Equipment Management

  Early Equipment Management (EEM) is a structured process focusing on reducing the complexity associated with the real-time operation and maintenance of equipment. EEM brings the principles of Lean to the design and manufacture of equipment. The Early Equipment Management strategy consists of three elements:

  • Design for Quality Assurance
  • Design for Maintainability
  • Life Cycle Costing

  Working with a team of engineers and maintenance personnel, we will develop a powerful EEM strategy ideal for your specific production environment which will result in equipment that is easy to operate, easy to maintain, and “right-sized” to aid in establishing flow and increasing your value add per square foot.
  
  

• Empowering the Workforce

  Empower your employees! Provide your process owners with the technical and social skills necessary to make better business decisions. Empowerment holds the key to long term sustainable improvement. To be successful in today’s operating environment, leadership must delegate authority, accountability, and freedom to act. This training session provides leaders with a guide to enhance their organizational change process and create a truly empowered workforce.
  
  

• Facilitator Training

  Today more than ever, teams play a central role in generating needed change and providing solutions to complex problems. A fundamental ingredient to enhance successful teamwork is the team facilitator. Developing a cadre of key people who will support and help sustain culture change and alignment to the organization’s vision and goals is an essential resource that organizations cannot do without. This training session provides the skills necessary for facilitators to foster and manage culture change and prepare them to get and keep teams focused on a process for achieving and sustaining continuous improvement.
  
  

• Focused Improvement

  Focused Improvement is one of the original pillars of TPM. The goal of Focused Improvement is to maximize OEE through uncompromising elimination of equipment-specific losses. In this training session participants will learn how to: use the Value Stream Mapping principals to identify critical pieces of equipment and their related impact on lead time, use the Focused Improvement Diagram (a visual systematic approach to the DMAIC process), document, monitor, and trend equipment related losses, and a process for determining the remedial actions necessary for loss control/elimination.
  
  

• Maintenance Planning and Scheduling

  Moving from a reactive maintenance organization to a proactive maintenance organization requires constant improvement in the way the maintenance process is managed. A key element of any proactive maintenance organization is its ability to properly plan and schedule repairs and PM’s. In this training session we will review the Maintenance Pillar of TPM, present the basics of a good maintenance planning & scheduling process, and introduce metrics that will help monitor results.
  
  

• Mistake Proofing for Machines

  The improper application of maintenance practices in a factory or facility can cause catastrophic failure and even jeopardize the health and safety of employees. Much like Poka-Yoke identifies the error and defects from a quality standpoint and FMEA helps identify potential issues with the machine design, Mistake Proof for Machines helps identify potential missteps in the application of maintenance practices and then takes the necessary steps to avoid any issues. This tool within the Pillar of Early Equipment Design/Maintenance Prevention Design, aids maintenance groups with the continuation of improving maintenance practices from all angles.
  
  

• Office TPM and Support Systems

  Unlike the production department, administrative and support functions such as planning, R & D, customer service, and accounting do not add value directly to the product. Yet they play a vital role in the organizations overall value chain. These departments must be flexible in order to respond to a rapidly changing business environment, outperform the competition, and win customer confidence. To accomplish these goals the support departments must understand their role in support of the TPM process in the production area, and ask what they can do to use the TPM principles and practices to enhance their own effectiveness? In this training session participants will learn the importance of educating, training and involving your administrative areas in TPM, as well as looking at actual examples of office TPM improvements and their associated cost/time savings.
  
  

• Predictive Maintenance Technologies

  Implementing an integrated multi-technology Predictive Maintenance Program, (PdM), can be a critical step toward achieving your overall performance goals. Well implemented PdM programs have been proven to reduce maintenance costs and increase reliability of production assets. This session will introduce predictive technologies by:

  • Reviewing cases studies and benefits of PdM implementations at several types of industries
  • Providing an overview of common PdM technologies such as vibration, motor current, infrared, and oil analysis
  • Discussing the relationship between various maintenance strategies such as PdM, preventive, proactive, and corrective maintenance
  • Introducing machinery wear mechanisms and failure progression and linking to the various PdM technologies
  • Providing options and alternatives for successful PdM program design and implementation
  • Presenting the newest technologies for PdM automation and integration into existing plant systems

  
  
  

• Problem Solving Using CEDAC

  This training session teaches an easy to use yet extremely effective team-based problem solving methodology that allows the users to go from symptoms to root cause. Learn a reliable nine step method for taking a current state condition (a problem, an issue, a target for improvement) to future state through a process of generating ideas and effective solutions. Using a powerful improvement process called CEDAC (winner of the Deming Prize), unlock your team's knowledge and creativity while learning how to integrate the CEDAC problem solving process with other improvement techniques such as Value Stream Mapping, Mistake Proofing, Quick Changeover, etc. CEDAC will likely be one of your most used process improvement techniques.
  
  

• Quality Maintenance

  The overall goal of the Quality Maintenance Pillar of TPM is to maintain your equipment in perfect condition in order to produce a perfect product. The Quality Maintenance pillar of TPM focuses on establishing equipment conditions with the goal of avoiding quality defects. To accomplish this, the Quality Maintenance Pillar uses the tools of Six Sigma to identify conditions that affect quality, establish a baseline for those conditions, and to create a process for periodic monitoring of those conditions. This training session explores the integration of TPM and the tools of Six Sigma to provide a well-ordered approach for acquiring total process control. Applying both of these methodologies in tandem presents today’s most powerful means of achieving your equipment performance goals of “zero breakdown” and “zero defects” with minimum maintenance costs. Note – this is an advanced workshop and requires participants to have a working knowledge of TPM and Six Sigma.
  
  

• Quick Changeover (The SMED System)

  TPM addresses the concept of the Six Big Losses, defined by Nakajima as formidable obstacles to equipment effectiveness. Implementation of the Quick Changeover methodology directly addresses one of these losses—set up and adjustment—and will help you dramatically reduce the downtime associated with make readies and other machine changeovers resulting in increased flexibility and customer responsiveness. The changeover methodology can also play a major role in reducing the time to complete major machine repairs, PM’s, and many more similar applications. This training session will demonstrate how you can use the principles of Quick Changeover to greatly improve a variety of maintenance and other activities found anywhere people and processes interact.
  
  

• Stores Management

  The great necessary evil of any maintenance initiative is the management of the spare parts department. Proper usage and storage of spare parts is not just an exercise in housekeeping, but a critical component in the success of your preventative and planned maintenance activities and an integral part of your overall maintenance improvement initiative. An effective stores management system will save your organization many thousands of dollars a year by ensuring spare parts are on hand and in good condition thus decreasing the potential for duplicate ordering and increasing equipment uptime. In this training session you will learn how to properly manage the storage and distribution of your spare parts.
  
  

• Team Dynamics and Conflict Resolution

  Leading a team of people who are trying to improve their operation is an exciting challenge. The team leader or manager needs to help the group move steadily ahead through the process of identifying, analyzing, and developing solutions to problems. Along the way, there are bound to be points of resistance which could lead to conflict among team members. A leader must have the skill necessary to guide the group past the conflict. To accomplish this, a leader needs to have a good understanding of the Conflict Resolution process and the ability to apply it. In this session participants will discuss their current approach to managing conflict, discover the eight key elements of an effective conflict utilization process, and take a Conflict Management Survey to help them better understand more about their individual actions and how they behave in conflict situations.
  
  

• TPM Audit and Accountability

  The success of your TPM implementation is often measured by the change in critical internal measurements such as throughput, quality, and safety. These numbers reflect how well TPM is working to improve the overall company, but those who are tasked with implementing TPM need quicker, real-time data to steer the implementation effort. Setting up a proper TPM auditing process can be the catalyst to improving the speed and quality of your implementation process. This session will teach you how to design, conduct, report, and use the TPM audit to improve your implementation effort.
  
  

• TPM Introduction and Awareness Sessions

  Get everyone involved and on the same page! This training has been designed to create awareness among your associates. During the sessions, we will carefully explain each of the basic TPM Pillars, how they relate to each other to create a natural synergy, and how they can result in an immediate return of the TPM investment when properly utilized in today's maintenance and facilities workplace. Actual case studies will be explored to show the rates of sustained improvements and to illustrate the relationship between TPM and the roots of Lean Manufacturing.
  
  

• TPM Tactical Planning

  With any TPM implementation, having a tactical plan is central to the success of the program. Understanding the elements of implementing TPM is important to putting together a solid tactical implementation plan. In this session, attendees will learn the basic foundations of a TPM tactical plan along with tools and techniques to customize the plan for their particular environment. Attendees will leave with a straw-man TPM tactical plan to build upon for their individual facility or company.
  
  

• Training and Skills Development

  This often overlooked Pillar of TPM usually gets put aside because conventional wisdom tells us each of the other TPM pillars require training, therefore we must already be performing the Training and Skills pillar. This training will show that having a specific focus on the Training and Skills pillar will enhance building your capabilities and reduce training cost at the same time. You will learn tools and techniques that will increase your training effectiveness in both hard and soft skills critical to an effective TPM implementation.
  
  

• Train the Trainer Program

  If you want to build your own internal in-house training capabilities, Productivity Inc. has developed a proven-process for the Training of Trainers. Through our multi-iteration, transfer-of knowledge, Train the Trainer Program, you can have the capacity to train your own employees, in specific improvement techniques, at your own pace. For organizations with a large employee community, rapid turnover, or a steady stream of new hires, our Train the Trainer Program can be the most effective means to achieve training of a critical mass necessary to continuous improvement.
  
  

• The Waste-Proof PM Process

  The process of performing maintenance is no different than any other work process. So process improvement applies to the maintenance activities as much as it does these other work processes. The Waste-Proof PM process is an inventive, hands-on waste reducing tool that identifies and removes waste within the Preventative Maintenance pillar of TPM. Natural work-teams learn and apply basic waste reduction methods and then apply these methods to real maintenance processes within the facility. When complete, the PM maintenance task is documented and standards are set to use as a reliable method.
  
  

Our Other TPM/Equipment Reliability Services:

• Consulting
• TPM/Equipment Reliability Assessments

Contact us to learn more about TPM/Equipment Reliability Training or to learn how to transform your organization into a Lean organization.