Total Productive Maintenance (TPM) & 5S

Course Introduction

Overview: This 3-day intensive training program is designed to equip participants with the essential knowledge and skills to implement Total Productive Maintenance (TPM) and 5S methodologies effectively. The course will delve into the fundamental principles, practical techniques, and real-world applications of these powerful tools for improving overall equipment effectiveness (OEE) and workplace organization. Through a combination of theoretical lectures, interactive discussions, and hands-on exercises, participants will learn how to identify and eliminate waste, improve equipment reliability, and create a safe, efficient, and productive work environment.

Key Focus Areas:

• 5S Principles and Practices
• TPM Pillars and Implementation Strategies
• Root Cause Analysis and Problem-Solving Techniques
• Autonomous Maintenance
• Planned Maintenance
• Quality Maintenance

Target Audience:

This course is tailored for operations managers, production supervisors, maintenance engineers, quality control personnel, and other frontline employees who are responsible for improving operational efficiency, reducing downtime, and enhancing product quality.

About the Course:

The course will cover a wide range of topics, from the basics of 5S to advanced TPM techniques. Participants will learn how to:

• Identify and eliminate waste through the 5S methodology
• Implement TPM pillars to improve equipment reliability and overall performance
• Conduct root cause analysis to identify the underlying causes of problems
• Perform autonomous maintenance tasks to prevent equipment breakdowns
• Develop effective planned maintenance schedules
• Implement quality maintenance practices to ensure product quality

Course Objectives:

Upon completion of this course, participants will be able to:

• Understand the core principles of TPM and 5S
• Apply 5S techniques to create a clean, organized, and efficient workplace
• Implement TPM pillars to improve equipment reliability and reduce downtime
• Conduct effective root cause analysis to identify and eliminate problems
• Perform autonomous maintenance tasks to prevent equipment failures
• Develop and implement effective planned maintenance schedules
• Improve product quality through quality maintenance practices

Course Outline

Day 1: 5S and TPM Fundamentals

• Morning Session: 
  • Introduction to TPM and its benefits
  • 5S principles and practices
  • Hands-on exercise: 5S workplace organization
• Afternoon Session: 
  • TPM pillars: Overview and implementation strategies
  • Group discussion: Identifying waste and loss in the workplace

Day 2: Root Cause Analysis and Autonomous Maintenance

• Morning Session: 
  • Root cause analysis techniques (5 Why’s, Fishbone diagram)
  • Case study: Applying root cause analysis to a real-world problem
• Afternoon Session: 
  • Autonomous maintenance concepts and practices
  • Hands-on exercise: Performing basic autonomous maintenance tasks

Day 3: Planned Maintenance and Quality Maintenance

• Morning Session: 
  • Developing effective planned maintenance schedules
  • Condition-based maintenance techniques
• Afternoon Session: 
  • Quality maintenance principles and practices
  • Group discussion: Implementing quality maintenance strategies

Course Outcomes:

By the end of this course, participants will have the skills and knowledge to:

• Create a safe, organized, and efficient work environment
• Improve equipment reliability and reduce downtime
• Identify and eliminate waste and loss
• Conduct effective root cause analysis to solve problems
• Implement autonomous maintenance practices to prevent equipment failures
• Develop and implement effective planned maintenance schedules
• Enhance product quality through quality maintenance practices

Conclusion:

By investing in this 3-day TPM and 5S training program, you can empower your team to drive significant improvements in productivity, quality, and overall operational performance. Don’t miss this opportunity to unlock the full potential of your workforce and achieve sustainable business success.