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Summary
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TPM / RCM includes training, materials, tooling, documentation, templates, and maintenance system startup assistance for:
- Development of a maintenance strategy,
- Visual factory maintenance management,
- Maintenance methods, and
- Changing culture for a company, plant, or department, i.e., provide a model to lead moving the decision-making closest to the operational value stream.
We review total productive maintenance principles and maintenance strategies, e.g., emergency, routine, and preventative maintenance. The eight pillars listed below support effective TPM and RCM startups.
1.Autonomous maintenance
5. Early management of new equipment
2. Planned maintenance
6. Process quality management
3. Equipment and process improvement
7. TPM in the office
4. Education & Training
8. Safety & Environmental
We focus on the #1 "autonomous maintenance" pillar since it is a good starting point to achieve benefits while we train and work hand-in-hand with operators, maintenance skilled trades, equipment suppliers, and purchasing. Reliability Centered Maintenance (RCM) and visual management form the foundation of our program. RCM is a strategy to help assure that the maintenance conducted is the right maintenance and that it produces the required equipment reliability.
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Who Should Participate
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Eight (8) to twenty (20) knowledgeable team participants from maintenance, manufacturing, manufacturing engineering, purchasing, tooling/equipment suppliers can be a successful RCM team. Team size depends on plant/enterprise size and scope.
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Deliverables
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The PTG trainer/facilitator presents and assists in executing the following:
- Setting TPM objectives; Identifying six big losses that impair equipment effectiveness and decrease run time; How to use visual factory management to improve TPM; How the owner-operator improves OEE and increases run time; How to calculate and understand Overall Equipment Effectiveness (OEE); Defining operation functions and performance standards, including material receipt, processing, tracking and handling Identifying the types of equipment and process failures
- Defining the most appropriate condition monitoring technologies and techniques
- Collaborating on the consequences of identified failures
- Designing and building a visual planning and control RCM program
- Carrying out the RCM program, updating ISO documentation.
- Establishing performance measures to control TPM progress.
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