Day 1

·       Pre Test

·       Introduction to Reliability

• Understanding Reliability
• Factors affecting reliability.
• Series & Parallel systems, Failure rate, MTBF
• Reliability Value Chain

·       Introduction to Maintenance

• Understanding Maintenance
• Maintenance Goals and Objectives
• Terms and Definitions
• Maintenance Value Chain

·       Maintenance Policies – An Introduction

• Corrective Maintenance
• Preventive Maintenance
• Predictive Maintenance

Vibration Analysis

• Infrared Thermography
• Ultrasonic Detection
• Oil & Wear Particles Analysis
• Proactive Maintenance
   Maintenance Excellence

What is it?

The Route, Key Success Factors.

·       Equipment Criticality Analysis

Definition, Concept, Benefits, Process.

·       Introduction to TPM

Philosophy, Evolution, Objectives.

·       Group Discussion & Quiz

Day 2

·       Overall Equipment Effectiveness (OEE)

• What is OEE?
• OEE Factors
• Calculating OEE
• Average OEE’s vs. World Class OEE’s

·       The Six Equipment Losses

• Breakdown Losses
• Setup and Adjustment Losses
• Losses due to idling and minor stoppages
• Reduced Speed Losses
• Product Quality Losses
• Startup/Restart Losses

·       The Five Causes of Breakdowns

• Poor Design
• Machine Basic Poor Condition
• Poor Operation Conditions
• Lack of Restoration of Deterioration
• Lack of Skills

·       Group Discussion & Quiz

Day 3

·       TPM Analysis Techniques

• Brainstorming
• The 5 Why’s
• Fishbone Diagrams
• Fault Tree Diagrams
• Failure Mode and Effects Analysis (FMEA)
• Value Stream Mapping

·       TPM Pillars

• 5S
• Autonomous Maintenance
• Focus Improvement (Kaizen)
• Planned Maintenance
• Quality Maintenance
• Education and Training
• Office TPM
• Safety, Health, and Environment

·       Group Discussion & Quiz

Day 4

·       Success Factors for Effective TPM Implementation

• Human Factor
• Operational Factor

·       Steps of TPM Implementation

• Announce Top Management’s Decision to Introduce TPM
• Launch Educational Campaign
• Create an Organization to Promote TPM
• Establish Basic TPM Policies and Goals
• Formulate Master Plan for TPM Development
• Hold TPM “Kickoff”
• Improve Equipment Effectiveness
• Establish an Autonomous Maintenance Program for Operators
• Set up a Scheduled Maintenance Plan for the Maintenance Department
• Conduct Training to Improve Operation and Maintenance Skills
• Develop Initial Equipment Management Program
• Implement TPM and Aim for Higher Goals

·       Group Discussion & Quiz

Day 5

·       Measuring TPM Implementation Effectiveness

TPM Indicators

·       TPM Case Studies in the Oil & Gas and Other Industries

• Problem Statement and Goals
• Data Collection
• Analysis
• Improvement
• Financial Savings

·       Discussion and Quiz

·       Post-Test