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In today's manufacturing industries, more and more companies are seeking ways to improve their plant’s performance through the application of continuous improvement tools such as TPM. Although it originated from the Japanese, TPM is not culture bound but rather its principles can be applied to any culture as long as people accept TPM as a way of life. TPM improves the manufacturing process through the utilization of employee involvement, empowerment and closed-loop measurement of results. Learn the basic principles of TPM and how it can be apply to your industry. It took me a lot of errors and mistakes to understand what TPM is all about. Let me share you my actual experiences in this training on TPM |
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As maintenance professionals we know the importance of maintenance to our organization goals and objectives. The difficulty is in translating the overall company strategy to a meaningful measure of performance. The old saying is that if you can't measure it, you cannot manage it " is as true for performance as for anything else. Much of what is meant by performance often appears to be immeasurable. It's OK looking at how things happened after the event and traditional measures can do this. What a manager needs is a much more dynamic, real time view of performance as it happens. People are central to this and qualities like motivation, confidence, leadership and perception are what is needed to be understood. But before we can use them we need to understand these measurements.
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MMP - Meaningful Measures Of Equipment Performance - Knowing MTBF MTTR, MTBA, MTTF & Weibull ( 2 days ) |
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OEE - Understanding Relationship Between Equipment Losses and Overall Equipment Effectiveness ( 1 day )
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OEE is the primary measure of performance in TPM. It is calculated by multiplying the availability, efficiency and quality rate of an equipment. This course allows us to understand the seven major losses we suffer each day and its relationship with OEE. Each losses is being discussed in detail and how it can reduced or eliminated. What is important is for our people to understand what losses our equipment is suffering and how to measure it. Is OEE a perfect measurement for your equipment. TPM experts say that once OEE reaches 85%, the equipment is already in a stage of World Class. Learn the truth about OEE and what it is all about. |
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OER - Optimizing Equipment Reliability – Gearing From Reactive To Proactive Maintenance, Streamlined RCM Approach ( 3 days ) |
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This course is a streamlined approach on RCM or Reliability-Centred Maintenance. This is a two in one course where the basic principles of RCM are covered and how we can derive an approach on determining our maintenance requirements for our assets based from our existing procedures. OER is a strategy and method for improving the effectiveness of current maintenance. programs and strategies. It starts with the existing maintenance program used within the plant. Working in cross functional teams from the shop floor, the team identifies what type of duplication exists within their own environment and what elements of the current maintenance program are useful and what are inappropriate. Once this is completed, the team can establish the most efficient and effective method for managing the maintenance of the asset.
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RCFA - Root Cause Failure Analysis – Understanding Equipment Failures (3 days) |
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AM1 - Understanding TPM’s Autonomous Maintenance - Operator’s 7 Step Journey to Empowerment ( 3 days ) of Jishu-Hozen ( 2 days )
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This course shows the importance and benefits of introducing an Autonomous Maintenance strategy and what it will achieve if correctly applied in the workplace. Autonomous Maintenance are the activities in which each operator performs daily cleaning, lubrication, inspection and parts replacement in order to establish Basic Equipment Condition. This course tells us the importance that Autonomous Maintenance and is not just the transfer of task and activities to operators but teaching operator that their responsibility does not end from just operating the machine itself. Autonomous Maintenance is about changing the mindset of operators from I fix you operate to operators take care of our equipment. This is about the 7 Step journey to operator’s empowerment.
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BMC - Basic Maintenance Concept – Understanding Reactive, Preventive, Predictive, Proactive Maintenance ( 1 day ) |
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This course covers the four strategies of Basic Maintenance Concept w/c are Reactive, Preventive, Predictive and Proactive and when each of them is feasible to use. Reactive Maintenance : This type of maintenance strategy simply means fixing it only when it fails as the saying goes when it ain’t broke don’t fix it when it fails then we come and fix it. In Preventive Maintenance, maintenance is performed on a fixed or scheduled Time-Based interval. Parts in which the rate of wear is directly related with age are subject to this type of tasks. Predictive Maintenance is performed not based on time but rather on the condition of equipment with the aide of diagnostic monitoring tools to determine the potential failures and lastly in Proactive Maintenance we are interested to Determine the Root Cause of the failure and correct it permanently to prevent recurring failures from recurring again in our equipments.
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PRO - Understanding Proactive Maintenance – Achieving A Culture of Reliability ( 1 day )
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It is a common practice due to lack of time and information that equipment and system failures are often investigated at a superficial level. As a result both operators and maintenance keep running unreliable plant, which cause repeated losses and become experts at fixing rather than eliminating the failure. This training you will learn to apply several practical systematic methods for analyzing performance problems to uncover the root cause that will eventually end all recurring problem making us proactive. Most maintenance are contended with fixing and repairing failures, in fact we accept them as a normal routine work, stock up piles of spare parts in our inventory to make sure that they are available whenever a failure occurs. Fixing failures is a thing of the past for companies who would like to improve their equipment reliability, their secret, they analyze their failures and determine the Root Cause of the problem so that appropriate solutions can be adopted. Trouble shooting is no longer an effective strategy. In today’s competitive world, the “Analysts” find real solutions to problems, that’s why the need to understand Root Cause Failure Analysis is a must. |
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This course explains the facts why typically an industry remain reactive in nature. Being reactive simply means that addressing a failure when it happens, failure will come first and maintenance react on it. Even with the best structure on Preventive Maintenance and top of the line software's at hand, PM can't capture all the failures. Failures are inevitable and occur in three patterns, Infant Mortality, Random Failures and Wear-out or age-related failures, Understanding this failure patterns will definitely allow us to have a better perspective about how to derive a holistic structure that will capture majority of these equipment failures. |
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PBMP - Practical Best Maintenance Practices for Industries ( 2 days )
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As we all know that the cost of Maintenance is generally much more than what it should be. Many techniques are rather talked about, learnt, planned and tried out but not much practiced maybe because it requires some discipline and detailed approach. With this in mind, I have designed this 2 days workshop to make you aware of what all maintenance systems and techniques are available which can be easily adopted to make your maintenance lean, productive and reliable by identifying and eliminating the wasteful practices. As the topic indicate, this will cover a wide range of maintenance practices which is a must for today's maintenance and hence will definitely reduce the cost of doing your day to day maintenance on your equipment and assets. It is a great pleasure to invite you all and to share and understand the best practices today in maintenance . |
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WCM - World Class Maintenance Management – The 12 Maintenance Disciplines ( 3 days )
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There is no silver bullet solution or rocket science program and strategy that can transform a plant’s reliability overnight, all will start with its basic foundation and that is through “EDUCATION”. Remember that reliability is not a program with an end but a culture that never ends, it is the same as any other continuous improvement philosophy . . . . . . |
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RELIABILITY & MAINTENANCE CONSULTANCY FIRM
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Where the learning just never stops . . .
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RSA
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PM4P - Understanding Planned Maintenance 4 Phases To Zero Unplanned Breakdown ( 3 days )
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This course covers the principles of TPM’s Planned Maintenance Four Phases to Zero Unplanned Breakdown Strategy. Phase One deals with Stabilizing MTBF, main activity involved here is restoration by establishing our equipment Basic Equipment Condition. Phase Two is all about Addressing Equipment Weaknesses in Design and addressing them to prolong the lifespan of parts Phase 3 and 4 of Planned Maintenance deals with developing a Maintenance Tasks Selection Diagram in order to classify which parts will fall on the different maintenance tasks available. Phase Four of Planned Maintenance is all about determining the parts that will undergo Predictive maintenance through a system known as Condition-Based Maintenance and the application and use of diagnostic tools to monitor equipment parts condition.
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FI - Understanding TPM Focused Improvement—Kobetsu Kaizen Pillar ( 1 day )
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Focused Improvement activities is used to accomplish maximum efficiency of individual facilities, equipment and manufacturing processes as well entire plants by thoroughly eliminating losses and improving performance. According to Suzuki, Focused Improvement includes all activities that maximizes the overall equipment effectiveness of equipment processes and plants through uncompromising eliminating of improvement losses and the improvement of performance. It is an arena of self-accomplishment for engineers and technical staff. These people upgrade their analytical skills in problem solving in order to improve the equipment and find abnormality which may take precautionary measures to eliminate them and improve OEE and eliminate all equipment losses. |
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LUB - Lubrication Strategy – Understanding Tribology and The Importance of Oil Contamination Control ( 2 days )
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This course covers a wealth of information on the need to implement a holistic and robust lubrication strategy in your plant. Learn why world class companies are adopting lubrication strategy, their benefits and what it can do to your plant. One of the problems most industries are facing is that we always end up being reactive despite our best efforts on Preventive Maintenance, frequent unexpected failures and breakdowns will always results to a high cost of maintenance due to a lack of an effective maintenance strategy. It is with our best intention to share with you this course and resources which can be adopted in your company. It is the intention of this course to share the information and experience on basic lubrication and contamination control and its benefits to plant production and maintenance people.
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RCM - Reliability-Centred Maintenance for Industries ( 3 days)
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CBM - Understanding Condition-Based Maintenance – Total Approach to Failure Prediction & Analysis ( 2 days )
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This course shows the importance and benefit of a Condition-Based Maintenance (CBM) program. The benefits of such program will be realized in greater equipment reliability and longevity while at the same time enhancing budgetary cost containment goals. Operations and Maintenance will make a sound maintenance & operating decisions based on actual equipment performance rather than relying on the old standard of Time-Based maintenance intervals or even less desirable circumstance or waiting for the equipment to fail in service. According to maintenance specialists, at least $250 billion of parts are wasted. Ineffective maintenance strategy is responsible for equipment failures, disrupted production schedules, delays in deliveries and poor production quality.
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Not all equipment are created equal even if they are of the same type of equipment. Much of the maintenance requirements have much more to do on how the equipment will be operated or the operating conditions of the equipment. This course covers the principles of RCM which is a process used to determine the maintenance requirements of any physical asset in its present operating context. It entails us by asking seven questions about the asset that is being maintained. This course provides an indebt details and understanding that the aim of maintenance is not about eliminating failures but rather understanding that each failure have their unique form of consequences and that the degreed of maintenance requirements should be based upon the consequences of failure itself. Likewise, this course allows us to understand that the best maintenance strategy should not just be confined to the limits of a traditional Preventive Maintenance only. Maintenance must understand that the behavior of failure occurs in three patterns which is Infant Mortality failures, random failures and age-related or wear out failures and that only around 20% of equipment failures conform to an age-related pattern.
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RSA |
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Inspired by change |
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• Gallery: New pictures for 2011 added from the gallery portion. • Newsletter: Aug. 2011 Edition finally released to our subscribers. Email me if you want to subscribe to our Newsletter. • 2012 Training Schedule: If you are interested to attend in any of our public workshop and master class for 2012. Send us an email or register online. • WCM Book: If you’re interested in buying the book on World Class Maintenance, The 12 Disciplines. Send me an email to reserve. WCM Book is now available. Get your copy now. • In-house Training :Should your industry be interested for in-house trainings we are now accepting regular schedules for in-house training for both local and international countries on courses that we currently offered. Contact us |
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Our Reliability Newsletter will be provided once a month to our valued subscribers. It provides highlights as well as issues and lessons regarding our most common link which is all about improving the reliability of equipment. |
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World Class Maintenance Management - The Twelve Disciplines Book is now available here. This is not only about the technical jargon on reliability and maintenance, it is a book that makes every single maintenance proud that they belong to the maintenance function. If you have been living through the day to day pressures of doing maintenance then this is your story. If you are interested in this book, send me an email. Click Here ! |
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Select the courses of your choice and it can be made available in CD . Click Here ! |
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We are very much flattered and humbled by your feedback and testimonies. Your messages are the main reason for allowing us to stay in this business. With all humility we say thank you and rest assure that we are continuously improving. Without your support in our training there won’t be us. Read More ! |
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• Registration at this forum is done through administration only. Should you be interested to join send me an email and we will provide you with a user ID and password. Visit my discussion board and forum . .
• Share what you know. Come and join our RSA Maintenance Forum. Send me an email |
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• If your industry is interested to join and participate in any of our upcoming public training and workshop for this year 2012 you may send us an email or simply fill out the registration form provided on our schedule site. You may Click here to visit our schedule training for 2012 Schedule. |
