Lean Maintenance (Total Productive Maintenance) 1 Day Workshop

Total Productive Maintenance (TPM) is often the first place to begin the journey towards Lean Transformation because it creates a manufacturing environment of stability, reliability, and capability. A stable infrastructure is a critical foundation that must be built before more tightly coupled Lean practices can be successfully introduced and more importantly sustained.

The goals of TPM include:

• Reducing unnecessary downtime due to breakdowns, minor stoppages, and quality problems
• Enhanced maintenance and frontline employee engagement and collaboration
• Systematically learning from equipment related problems so that root causes can be identified and addressed
• Fostering productive dialogue between production managers, employees, and maintenance staff.

This one-day workshop will introduce key TPM concepts, root cause analysis and the strategies for a successful TPM pilot and wider journey

Participant profile 

This introductory course is designed for frontline employees, maintenance and production supervisors, and managers interested in deploying TPM.

Course outline

Morning Session

• The History and Evolution of Maintenance in the Context of Lean Management
• The 5 Pillars of TPM (Continuous Improvement in OEE, Maintenance Asset Care, Operator Asset Care {Autonomous Maintenance}, Skills Development, and Early Equipment Management)
• The TPM Model of:
  1. Measurement Cycle (Historical Analysis, OEE, 6 Losses)
  2.  Condition Cycle (Criticality Assessment, Condition Appraisal: Spot the Rot, Refurbishment Plan and Spares, Asset Care)
  3. Problem Prevention Cycle (Best Practice and Problem Prevention)
• The 4 Core TPM Metrics for the Attainment of Flow

Afternoon Session

• Current State Diagnostic Audit Exercise
• FMEA to Mitigate the 80/20 Breakdown Risks and Exercise
• Predictive Maintenance – Methods of Predicting Time between Equipment Failures
• Cultural Considerations and Team Working
• 5S Workplace Organisation and Impact on TPM (the surprising root cause of 40% of equipment breakdowns)
• Quick Changeover and TPM
• Continuous Maintenance Improvement Visual Management System
• TPM Implementation Roadmap Exercise

Trainer profile

Andy Brophy is a Lean & Innovation Improvement Advisor. He has been working in the Lean field for the last 15 years with a diverse range of organisations including manufacturing, government, services, software development, and hospitals.

Andy is a professional engineer and holds a 1st Class MSc in Lean Operations from Cardiff University and is Six Sigma Black Belt certified. In May 2010 he published the co-authored book Innovative Lean with John Bicheno of the Lean Enterprise Research Centre in the UK. This work is primarily based on the power of harvesting and implementing employee ideas and creating an innovative and empowered workforce.

In 2011 he was selected by Pearson’s the world’s largest book publisher to write The Financial Times Guide to Lean. The book is currently being translated into Spanish, German, Dutch, and Japanese. The book is currently undergoing assessment for The Shingo Prize Award in the USA.

In 2015 he is scheduled to publish a co-authored book with three USA based authors. They are API’s Improvement Advisor Cliff Norman, Yedda Trawick of Care Oregon, and Jane Norman of PKP Inc. The book is titled Lean Healthcare and The Science of Improvement. This research will explore Lean Healthcare with emphasis on Deming’s System of Profound Knowledge using the internationally adopted Improvement Model within healthcare. This pioneering book aims to alloy these two potent improvement philosophies to advance the accomplishments already realised through the application of Lean to healthcare.

Clients he has served previously include: Dublin Airport Authority, Department of Social Protection, ESB, St. James’s Hospital, HSE National Logistics and Distribution Centre, NHS King’s Hospital London, Enterprise Ireland, Central Bank Mint, Lisheen Mine, Abbott Vascular, Grant Engineering, Klasmann Deilmann, Tour America, Top Flight, Height for Hire, and Directski.

Booking Details

Duration: 1 day

Location: Dublin (Louis Fitzgerald Hotel)

Date: TBC

Price: Available on request

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