Maintenance management according to TPM and TOC
- Reduction of losses in the production connected with failures and unplanned machine idle times
- Acquiring skills of the proper implementation and management of TPM
- Using the methods, tools and indicators
- Learning about the problems ad solutions occurring in different plants that have implemented TPM
- Exchange of experiences in the field of soft aspects of TPM, such as motivating and involving workers
day 2 h. 9.00 - 16.00
day 3 h. 9.00 - 16.00
fax: +48 32 720 20 52
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regarding the accuracy of selected training
- Machine in the systemic perspective (division of machines and equipment into elements: critical, significant, general purpose elements; Condition Monitoring; trending; analyzing data from the machines)
- Definition and approach to TPM (Total Productive Maintenance) – key elements, tools for identification and elimination of losses, methods of efficiency improvement, basic documentation, improvement of the efficiency of using resources, bottlenecks in production
- Aims of implementing TPM
- Losses in the production systems (overview, identification, methods of elimination)
- Comparison of TPM and TQM (assumptions, tools, aims of implementation)
- Practical grounds for the implementation of TPM
- Overview of the exploitation methods (technical maintenance) – advantages and disadvantages, required documentation, comparison, planning the renovations, including:
- precautionary (preventive)
- until the event of failure (damage)
- dependent on the machine condition (predictive) [PDM - Predictive Maintenance]
- proactively preventive
- Implementing TPM on different levels of the production plant
- Process quality indicators in TPM (definition, selection, presentation of results and its significance in the improvement of loss elimination):
- OEE (Overall Equipment Effectiveness)
- MTBF (Mean Time Between Failures)
- MTTR (Mean Time To Repair)
- KPI (Key Performance Indicator)
- Stages of implementing the TPM program (structure, methods, milestones)
- Idea of the Autonomous Maintenance (preparation, implementation, control and system management)
- Information used in TPM (definition, standardization, acquiring and using in the production process)
- SMED, 5S, SixSigma (analysis, documentation, implementation on different levels of production)
- Production scheduling
- Costs of implementing TPM (elements affecting the costs, examples of calculations)
- Basics of the Theory of Constraints (TOC)
- Basic tools used in TOC, including: CRT – Current Reality Tree, EC - Evaporating Cloud, Prerequsite Tree, IOM - Intermediate Objective Map
- Practical exercises
Classrooms and laboratories are air-conditioned, large and spacious. Workstations for the participants have been fitted with specialist equipment. The participants have at their disposal tools used in the industrial metrology and additionally - a coordinate measuring machine and measuring arm.
Our trainers have extensive technical knowledge and broad experience supported by years of documented work in various implementation projects. What’s more, they are experts for national journals and offer their consultation in different projects. During the trainings, their main focus is on passing knowledge of the real examples they have encountered in their professional work.
Our trainers are open to all suggestions made by the participants. It is very common that during trainings the group discusses the issues beyond the scope of the standard program that cover specific aspects of the students work.
Completed courses also lead to cooperation between EMT Systems Ltd. and representatives of industrial facilities in the following areas: projects, modernization and commissioning of the machine hydraulic systems and technological lines..
Benefits for participants:
Skills acquired during the course will allow the participants to effectively and appropriately apply TPM in their production plant, increase safety and comfort of work and enjoy considerable benefits resulting from:
- Increasing the efficiency of machines, devices and human labor
- Reduction of mistakes, breakdowns, micro down times etc.
- Reduction of production and equipment maintenance costs
- Enhancing the quality of manufactured products
The essential elements of the training courses organized by EMT-Systems are content, well-qualified trainers and modern equipment. However, as the Engineering Training Center we also pay attention to the highest quality of catering services.Each day of the course the participants receive:
- A two-course lunch – our cuisine is a combination of traditional, home-made meals known from the modern milk bars and dishes served in restaurants. Every day, there is a selection of soups and main courses.
- Unlimited access to our EMT Coffi Di‘Italian Espresso Bar. During short breaks in classes our students may use the fully stocked coffee bar:
- THERMOPLAN BW 4 – a professional Swiss coffee machine used in best cafes. You may choose the coffee you like best - Cappuccino, Espresso, Americano, Caffe Latte and Turkish Coffee.
- Traditional vending machine serving different types of coffees and hot beverages such as tea, hot chocolate or borscht.
- A selection of kettles, coffees and teas for self service.
- Sparkling and still mineral water, squash.
- A selection of cookies and fruit.
Total Productivity Maintenance is one of the most important tools of effectively managing production companies. Technique invented in 1970s in Japan has been widely used in factories around the world increasing the productivity, enhancing quality, reducing costs and, as a result, increasing profits. TPM is based on the assumption that involving all employees in the process of building effective prevention system, systematic reduction of losses through problem solving and standardization are a key to achieve the goal of three zeros: zero breakdowns, zero defects and zero accidents. TPM is a tool implemented and used in such companies as Volvo, FIAT, Iveco, Mirelli, Unilever, PepsiCo, Wrigley or Heineken.