PRODUCTIVITY LEAN SERVICES INC. | PRODUCTIVITY EUROPE
This 5-day certificate program is designed to start you on your journey toward World Class Reliability with 9 essential tools for managing and improving the maintenance process.
April 29 - May 3, 2019
Moving from a reactive to a proactive maintenance environment has a big and positive impact directly on your bottom line. Did you know that when equipment plans its own downtime (i.e. a breakdown) it is ten times more costly both financially and in terms of capacity losses to get back to a safe, efficient ‘run-ready’ state?
Chances are you already know you must do something to improve the reliability of your equipment but you might not know exactly what to do or how to get started. Held on the campus of The Ohio State University, this one week, fully-accredited program has been designed to introduce you to nine fundamental techniques for doing just that! Get started on your journey to World Class Reliability today.
Upon completion of this program, you will be awarded the Manager of Maintenance Improvement Certificate by Productivity Inc. and The Ohio State University. Graduates of the program earn 4 CEUs.
This program will teach you…
Establishing a Zero Failure Culture
The goal of the maintenance process is to minimize equipment life cycle cost and achieve zero speed losses, zero unplanned downtime, zero safety incidents, zero quality issues, etc. The principle of zero failures states that abnormalities that go unnoticed or are ignored eventually lead to some type of failure. During this session, we will carefully explain each of the basic principles of proper maintenance and how they relate to each other to create a natural synergy, enabling you to achieve the goal of zero. You will gain a good understanding of these principles and how and when to implement them to get the greatest return in the shortest possible time. Actual case studies will be explored to show the rates of sustained improvements and to illustrate the relationship between a proper maintenance process and the roots of Lean manufacturing.
Establishing Key Maintenance Metrics and Measures
Determining the focus of your maintenance effort depends on where the data tells you to go. What is happening to the equipment and how it is performing is found in the numbers, not intuition. This session will teach the basic maintenance performance metrics -- MTTR, MTBF, Schedule Compliance, Weighted Identifier, etc. -- and how they are calculated. It will also teach you how to break down the data and show you how affecting this data will move the numbers in the right direction.
Autonomous Maintenance (AM)
Autonomous Maintenance is a proven process that partners operators, maintenance technicians, engineers, and leaders in the operation and maintenance of equipment. Properly implemented, AM can eliminate the causes of 40-60% of unplanned downtime. This module covers the seven steps of Autonomous Maintenance and equipment related visual management and how to use tools such as provisional standards, one-point-lessons, improvement bulletins, etc., to stabilize equipment performance and stop deterioration.
The Waste Proof PM Process
Maintenance improvement 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, thus improving MTTR. This module 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.
Focused Improvement (FI)
The goal of Focused Improvement is to maximize OEE through uncompromising elimination of equipment-specific losses. In this module you will learn how to use the Value Stream Mapping principals to identify critical pieces of equipment and their related impact on lead time. You will then learn how to document, monitor, and trend equipment related losses, and a process for determining the actions necessary for loss control/elimination.
Machine Failure Analysis
Key to ensuring a maintenance process that continually strives for Zero Failures is the skill to analyze those failures and eliminate them from ever reoccurring in the future. Machine Failure Analysis incorporates standard problem solving methods with maintenance system outcomes to produce a problem solving technique designed specifically to analyze and eliminate machine failure. This team-based approach to maintenance improvement looks at the failure on a physical, systemic level. Mechanical attributes, spare parts, preventative maintenance procedures and employee skills are all analyzed and reworked to ensure the failure never returns.
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 PMs. In this session we present the basics of a good maintenance planning & scheduling process, and introduce metrics that will help justify the program.
Managing The Storeroom & Spare Parts
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 thousands of dollars by ensuring spare parts are on hand and in good condition, thus decreasing the potential for duplicate ordering and increasing equipment uptime. In this module you will learn how to properly manage the storage and distribution of your spare parts.
Setting Standards and Leading The Effort
Standard work is a key element in the elimination of waste and a critical component of both operator based maintenance (Autonomous Maintenance) and maintenance improvement. In this module, you will learn a proven methodology to develop a standard procedure, and then apply document control and visual workplace principles and techniques to train others in their new best practice.
Sustaining the gains made through implementation of the tools learned during the certificate program will be vital to ensuring ongoing maintenance improvement. As we wrap up the week’s learning we will discuss the transformational issues that must be addressed and the leadership techniques that must be in place to ensure long-term success.
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Accommodations: A block of rooms is being held for Productivity Inc. MMIC attendees at The Blackwell Hotel on The Ohio State University campus. Address: 2110 Tuttle Park Place, Columbus, Ohio 43210.
Productivity Inc. attendees receive a reduced rate of $145.00 per night, single or double occupancy. Rate includes hot buffet breakfast. Please call 614.247.4000 or toll-free 866.247.4003 for reservations, and identify yourself as a Productivity Inc. MMIC program attendee. The special rate will be available until four weeks prior to the event; after this date the hotel cannot guarantee availability.
For more information on The Blackwell Hotel, please visit www.theblackwell.com. The hotel is approximately 8 miles from the Columbus International Airport.
Cancellation policy: Prior to the start of the session, registrations may be transferred to a colleague without charge. To be considered for a refund, we must receive notification of cancellation in writing no later than 30 business days prior to the event. Cancellations received within 30 business days of the start of a program are subject to the full registration fee; this money will be held on account for up to one year for use at a future workshop or conference. Cancellations received within 10 business days of the start of a program will be assessed a fee equal to 20% of the registration fee; the remainder of the fee will be held on account for up to one year for use at a future workshop or conference. If no notification of cancellation is provided, registration fees will be forfeited. There is a $200 processing fee for all cancellations. No refunds or credits will be issued once a session is underway. On rare occasions, circumstances may make it necessary to cancel or postpone an event. We encourage attendees to book refundable/reusable airline tickets. We will not be responsible for incidental costs incurred by registrants.
By registering for this event, the registrant hereby acknowledges and agrees that any photographs or videos taken during the event may be used in marketing efforts, including but not limited to news and promotions (web/print) without compensation to the registrant.
Note: All registrant applications will be evaluated for acceptance into the program. Consultants and university faculty may not be permitted to attend this event.
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