PLANNED MAINTENANCE Planadong Alaga

MANAGING FOR GLOBAL EXCELLENCE:
PLANNED MAINTENANCE




DURATION: 1 Days (8 hours)

TARGET AUDIENCE: Maintenance Technicians /Engineers/ Supervisors / Managers/ Plant Managers

PRE-REQUISITE: 7 QC Tools, Basic SPC, Introduction to TPM

COURSE DESCRIPTION:

Planned Maintenance (PM) is one of the principal features of Total Productive Maintenance (TPM). It focuses on implementing planned maintenance system by maintenance specialists. Corrective, Time Based and Predictive Maintenance are the three main activities to set-up and perform. This pillar is focused mainly on the maintenance group.

Planned Maintenance can bring about higher equipment output, zero defects, and increased machine availability. It also is aimed at improving the quality and capability of maintenance technicians.

This course is developed to introduce to all engineers/supervisors/managers/ plant managers, the different aspects of Planned Maintenance.

The course is based on the actual hands on experience of the course author in the implementation of PM on semicon industry. It will be highly interactive. Concept presentations, discussions, and group participation are integral part of the course. Hands on exercise will be a major activity.


COURSE OBJECTIVES:

At the end of the course, the participants should be able to:

• Better understand the Planned Maintenance (PM) function and purpose

• Learn and apply the different components of PM

• Develop the initial skills and knowledge in implementing PM in the factory





COURSE OUTLINE:

 Brief Introduction to TPM- JIPM
 History and Origin
 Basic Terminologies and Definitions

 Planned Maintenance
 Basic Composition and Functions
 KPI
 Components of PM
 Exercise and Workshops on each Steps

 Related Tools required to perform effective PM

Starter for TPM

I have mentioned in earlier blog that the top management must initiate the conversion of existing system of the company to TPM . And, that benchmarking visit will very beneficial to the management team to have an initial understanding of how TPM works and its visible effects.

The continuation of all the activities will then rely on the people that will assigned to run the system. This group assigned is headed by a senior manager, reporting to the GM or President and is designated as TPM Office Department Manager (or Director depending on company structure). He will then prioritize staffing his team for the different pillars. Each TPM Pillar may have one staff depending on the size of the entire organization.

This group is responsible for the TPM start-up.

If you need more details... you have my email to contact.

Happy starting....

God bless!

Want to See TPM in Action?

I've been trained in JIPM- Atlanta Georgia, USA , and TPM Tokyo, Japan. There are many affiliated companies with JIPM or Japan Institute of Plant Maintenance who has achieved significant improvements and thus were awarded with TPM Excellence Awards. And all of them are very much willing to open their doors for benchmarking and sharing.

Needless to go far, locally, we have companies in the Philippines which have embarked on their TPM Journey and foremost of this is TIPI- Texas Instruments, Phil. Inc. I am fortunate to have several visits to this company and see on a first hand basis their activities and results of their TPM. TIPI has been a recipient of TPM Excellence Award. The first company in the Philippines and I believe in South East Asia to be rendered with said honor.

It will be very good activity for the top management of a company who wishes to pursue TPM to do benchmarking visit. Options I have laid above.

Want to learn more and achieve sucess in your TPM Launch.... contact me for details.

God bless!

Why TPM?

If it's originated in Japan it must be good, right? But, not just because it started in Japan that many companies establish their own TPM System.

Foremost of this reason is the growing need of the manufacturing companies to involve their employees in the quest for excellence. And TPM is the best System that ensures Total People Involvement. By total, it means that the President or CEO of the organization to the janitors are involved and have defined roles to play.

Second reason is the TPM Structure which brings about cohesiveness, and unilateral approach towards Continuous Improvements. TPM as a System defines a well coordinated Structure that simplifies and clarifies the overlaps between traditional organizational set-up and the TPM structures. Thus, the key results are intermingled yet supportive of each other and has no duplications.

Third reason is the Morale Boosting effect of TPM on people as team members exercise autonomy and flexibility. Successful companies in TPM does not only achieve tremendous KPI (Key Performance Indicators) improvements to the tune of 30% but also shows significant reductions in absenteeism, tardiness and sick leave rates.

If youwant to implement this in your company, just contact me for coaching and details...

God bless.

TPM Common Misconception

TPM is by all measure and significance is well known and implemented in Japan where it originated in the 60's.

However, the fan-out so to speak in many other countries were full of maladies and incongruencies to the real intent and purpose of TPM.

One of which is the understanding that TPM is another PROGRAM...

Many companies start with vigor and much funfare, but as soon as the TPM driver moves out or is taken out, the TPM fades away.

Another wrong concept of TPM is that is a rah rah drive for 5S! Short sighted as it is , people claim they implement TPM because they are doing 5S. My goodness. Believe me, there are companies that started TPM with 5S and end with it.

Another misconception is that TPM is only for Maintenance people. And they think TPM means Total Preventive Maintenance. Thus, involvement are limited and is purely driven by Maintenance folks.

If you want to learn more about it, just give me an email and I'll gladly respond to you.

God bless.

How to Start-up a TPM

TPM is not a program but a System, thus, it requires total management support and backing before a company can plunge into it.

That is the first step, management commitment. This must be celebrated and ceremonies must be held. You can call this as "Kick-off" and there are many ways of doing it. It must involve all the people in the organization from the top rank to the lowest level plus contractors, suppliers, business partners and special customers.

You have to have a TPM Champion assigned who must have undergone TPM Training, or a TPM Consultant.

If you want more details just give me a note at : richbenj.santiago@gmail.com or benj5_santiago@yahoo.com.

God bless!

Origin of TPM- How I Got to Know

TPM is made in Japan!

It was originally introduced in Japan for the production shop floor in 1971 but was transformed to cover the entire operation in 1989.

On its re-introduction to cover the overall facets of production, the TPM Pillars put up became 8 from original 5 Pillars that included:

1. Focused Improvement (Kobetsu-Kaizen).
2. Autonomous Maintenance (Jishu-Hozen)
3. Planned Maintenance
4. Training and Education
5. Initial Flow Control (Equipment Focused only)

The 1989 additions are:

6. Quality Maintenance (Hinshitsu-Hozen)
7. Administrative TPM
8. EHS- Environment Health and Safety

Pillar 5 also has been expanded to cover new product or process introductions.

I'm very familiar and would consider myself expert in all the Pillars and how it is implemented as I have taken a Certification Training and completed said TPM Course in Atlanta Georgia and Tokyo Japan.

I have implemented said system holistically and in part in the companies I worked with.

Will tackle the major features of each pillars on the next blog.

If you have comments and or queries, please feel free to email me at : richbenj.santiago@gmail.com

God bless!