Manager of Maintenance Improvement Certificate - Fall 2020
Oct. 26-30 – A 5-day Consultant-Led Fully-Accredited Virtually Delivered Program
Provides an understanding of the core techniques for improving manufacturing performance and equipment reliability. Designed for maintenance and production resources seeking a solid understanding of the fundamental techniques for improving the maintenance process. Fully accredited...Register Now Faxable registration
Where are you today ?
When equipment plans its own downtime it is ten times more costly to get back to a safe, efficient, “run-ready” state!
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.
This one week, fully-accredited program has been designed to introduce you to nine fundamental techniques for doing just that! Your own examples will be discussed during the session to help illustrate methods being covered. 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 Fisher College of Business at The Ohio State University. Graduates of the program earn 4 CEUs.
Designed for maintenance and production resources seeking a solid understanding of the fundamental techniques for improving the maintenance process.
This program will teach you…
- Learn how to use data to make improvements.
- Understand how to create provisional standards and one-point-lessons.
- Learn to properly plan and schedule repairs and PMs.
- Discover how to eliminate equipment-specific losses.
- Understand the proper storage and distribution of spare parts.
DAY 1 – MONDAY
10:00am – 5:30pm EDT
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.
DAY 2 – TUESDAY
10:00am – 5:30pm EDT
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.
DAY 3 – WEDNESDAY
10:00am – 5:30pm EDT
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 a
DAY 4 – THURSDAY
10:00am – 5:30pm EDT
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.
DAY 5 – FRIDAY
10:00am – 4:00pm EDT
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.
WHAT PAST ATTENDEES ARE SAYING…
“Very detailed and the training flow perfectly matched a real world maintenance process. I recommend this training to maintenance professionals, operating managers, machine operators or anyone willing to improve their processes.”
Lee Williams – Facilities and Equipment Manager – Pharmavite/Nature Made Vitamins
“I selected this program over others because of the focus on continuous improvement
and was not disappointed.”
Jim Cochran – Project Management Director – American Sugar Refining, Inc.
“I’m impressed. This has been a great learning experience.”
Romey Bryant – Manager of Production Support – Premix, Inc.
“Extremely knowledgeable instructor engaging with well thought-out examples.”
Steve Winters – Facilities and Maintenance Manager – Northrop Grumman
“Terrific! Finally a lean-based TPM training. Ellis is fantastic and well-qualified.”
Ryan Romander – Lean Project Manager – Basic American Foods
“Excellent, empowering and direct.”
C.Scott McFarland – Maintenance Manager – Newell Rubbermaid
“Enjoyed the program, received good information and intend on implementing
positive change at my sites.”
Ken Fabrizio – Engineering & Maintenance Manager – Allnex
ABOUT YOUR HOSTS
Productivity Inc. is a leading consulting and training firm that helps organizations build new capabilities, save money, and grow. We focus on three progressive strategies: Operational Excellence, Innovation Systems and Leadership Development.
Working together, these strategies provide the means to continually refresh a company’s value proposition while making the organizational changes needed for daily improvement and sustainable growth.
We pioneered the implementation of Lean and TPM methodologies in manufacturing in the late 1970s. Since then, we have extended these methodologies across a wide range of industries, including healthcare, finance, and other service industries.
Today, our time-tested management system, motion™ provides organizations with:
- a uniquely comprehensive approach to implementing Lean across an entire enterprise, incorporating assessment, leadership, and business renewal.
- a robust process for innovation to develop an organization-wide capability to create new forms of value – reliably, predictably, repeatedly.
More than simply a Lean consulting firm, Productivity Inc. can provide you with a variety of methodologies to keep your enterprise in motion™.
THE OHIO STATE UNIVERSITY’S FISHER COLLEGE OF BUSINESS
Since 1916, The Ohio State University’s Fisher College of Business has produced exceptional leaders who meet the challenges of a changing global business environment through creative and effective solutions. As a result, Fisher’s reputation continues to rise and is reflected in rankings which place the college among the top 15 Business Schools in the nation at the undergraduate and graduate levels of public universities.
Today, Fisher College of Business Executive Education continues to provide growth opportunities to business professionals seeking to increase their knowledge, insights and intuition. Their executive-level degree programs are comprehensive, integrative and examine today’s issues from every angle to give you a total business perspective.
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Call us: 1-800-966-5423 or 203-225-0451