TPM Core System
Keysense's TPM (Total Productive Maintenance) Core System is a foundation program leading toward Maintenance Excellence.
It is a framework consisting of 5 sub-systems that serve as core activities of any front-line asset care system. It addresses the conflicts between equipment users and maintainers and provides a sense of "ownership". It teaches OEE and practical ways to reduce equipment losses.
What is next?
Work Maganagement System
A work system for planning, scheduling, executing, and tracking maintenance activities, including preventive maintenance, corrective maintenance, and predictive maintenance. It is also a performance system monitoring and measuring the effectiveness of maintenance operations, using key performance indicators (KPIs) such as equipment uptime, maintenance costs, mean time between failures (MTBF), and mean time to repair (MTTR).
Total Productive Maintenance (TPM) is a maintenance philosophy that aims to improve the productivity and effectiveness of equipment by involving all employees in the maintenance process. The core system of TPM includes a series of activities and practices that are implemented to achieve the TPM goals. The outcome of a successful TPM system improves Overall Equipment Effectiveness (OEE) and reduces downtime and maintenance costs.
TPM Core System Workshop
Keysense's TPM Core System is a framework that helps organizations to install the most critical systems in day-to-day equipment care and maintenance routines. While the traditional way of implementation may take time, our TPM Core system training and workshops enable manufacturing plants to install highly effective asset care systems rapidly.
The workshop is a real-life implementation of five TPM sub-systems at a focus area or pilot line at a client's facility and turns it to become a "center of excellence" This shall be used as a seed to enable large-scale implementation across the enterprise.
Workshop Duration
The shortest duration of the workshop is three days on-site with an additional day of preparation to ensure the success of the workshop. The actual duration could be adjusted depending on the complexity and condition of the existing equipment.
Who Should Attend
This a learning by doing workshops. A typical workshop is led by the production and maintenance manager, production and maintenance engineers, maintenance planners, and experienced operators. It is usually supported by Lean Practioner or Continuous Improvement team.
Workshop Outline
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Day 0: Preparation
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Scope and Budget
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Leadership Onboarding
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Data Collection
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- Day 1: Engaging
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Team On-boarding
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Understand TPM
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Culture and Behaviours
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What is Baseline?
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6 Losses and OEE
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Day 2: Equipment Condition Appraisal
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Criticality Assessment
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Types of Defects
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Defect Walks
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Condition Appraisal
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Restoration Plan
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Day 3: Daily Asset Care Routine
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Condition Based Monitoring
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Understand CLIT
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What is CL?
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Identify CLIT & CL points
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Develop Master List
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Day 4: Improve OEE
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AM & PM integration
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Attack the 6 losses
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Problem-solving
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Systems Design
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Day 5: Sustain
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TPM visual board
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Improvement Target
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90-Day Action plan
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Teach Back Presentation
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Total Productive Maintenance (TPM)
