Management Technologies, Inc. Operational Excellence Training Curriculum

Transcription

1 , Inc. Operational Excellence Training Curriculum, Inc West Big Beaver Suite 105 Troy, MI (248) M03183A, Rev. 6

2 TABLE OF CONTENTS LEAN MANUFACTURING Lean Value Stream Mapping Workshop... 2 Creating Continuous Flow...3 TOTAL PRODUCTIVE MAINTENANCE (TPM) Understanding and Managing TPM Organizational Change 4 TPM Implementation 4 TPM Excellence Overview...5 TPM Instructor/Facilitator Training..5 TPM Executive Cascade Training. 6 FOCUSED IMPROVEMENT Focused Improvement 6 Quick Setup and Changeover Workshop Measuring Equipment Performance...7 Why-Why Analysis Workshop....8 AUTONOMOUS MAINTENANCE Autonomous Maintenance Workshop 8 TPM Basic Training Series for Shop Floor Teams 9 One Point Lessons S Visual Management Workshop 10 PLANNED MAINTENANCE Introduction to Preventive Maintenance...11 Managing Maintenance Workshop Preventive Maintenance Planning and Scheduling...12 Preventive Maintenance Implementation Series...12 EARLY EQUIPMENT MANAGEMENT Early Equipment Management Workshop M03183A, Rev. 6 1

3 Learning to See Value stream maps are the blueprints for lean transformations. This workshop shows you how to make and use them, based on the material in the Lean 's groundbreaking value stream mapping workbook, Learning to See. Working with a simple factory example, you ll learn how to see value, differentiate value from waste, and eliminate the sources of waste by creating accurate current state and future state maps for each of your product families. Lean Value Stream Mapping Workshop covers the following topics: Benefits of Lean Manufacturing and Value Stream Mapping Current State Map Characteristics of a Lean Value Stream Future State Map Action Planning to achieve Future State Length: 1-2 days M03183A, Rev. 6 2

4 In this sequel to Lean Value Stream Mapping, you will learn to create continuous flow in the critical pacemaker processes and other production cells. In Creating Continuous Flow Workshop, You will learn how proper cell design involves far more than moving machines together. This workshop uses simple factory examples to show creation of flow through proper cell design, such as analyzing operator work elements, distributing the elements in relation to takt time, selecting the right level of automation, and using a system of standard work audits to sustain higher performance levels. Creating Continuous Flow Workshop covers the following topics: Definition and benefits of Continuous Flow and key Lean concepts What is Work Machines, Material and Layout for Flow Distributing the work Connecting to the Customer and Regulating the Flow Implementing, Sustaining and Improving Length: 1 day M03183A, Rev. 6 3

5 TRAINING AND EDUCATION This seminar focuses on the human side of TPM implementation, with emphasis on the organization transition Length: 4 hours TRAINING AND EDUCATION This course provides the skills required to manage your TPM implementation. When you apply the techniques taught in this course, you will: Stay on schedule Control costs Meet objectives Minimize disruption to the regular work flow of the organization The course materials include forms and a Microsoft Project template plan for the initial stages of TPM implementation of a plant. Length: 1 day M03183A, Rev. 6 4

6 TRAINING AND EDUCATION This overview provides a high-level perspective of TPM benefits, activities and implementation processes. Upon successful completion of this seminar, you will be able to: Define Total Productive Maintenance (TPM) Describe the benefits of TPM Describe the purpose and activities of each TPM pillar Define the steps for successful implementation of TPM Length: 4 hours TRAINING AND EDUCATION This comprehensive ten-day course is designed to prepare TPM Facilitators and Instructors to train staff in TPM skills and concepts and to lead the initial stages of TPM implementation in the workplace. This course includes extensive shop floor and classroom activities and covers the following topics: Definition and basic concepts of TPM Benefits of TPM Overview of the Eight Pillars of TPM (248) First three steps of Autonomous Maintenance Focused Improvement Planned Maintenance TPM implementation planning Coaching for TPM Length: 10 days M03183A, Rev. 6 5

7 TRAINING AND EDUCATION This one-day course with pre-work booklet is designed to enable and motivate corporate, division-level and plant executives and upper managers to support TPM implementation. The course uses lecture, floor activities and classroom activities to teach TPM concepts and demonstrate the value of TPM to organizations at several levels. TPM Executive Cascade Training covers the following topics: Definition and basic concepts of TPM Benefits of TPM Overview of the Eight Pillars of TPM Measuring equipment performance TPM In Practice TPM Implementation (executive and management perspective) Length: 1 day plus pre-work FOCUSED IMPROVEMENT This one-day course presents the concepts of Focused Improvement, sometimes called the "money-maker of TPM". Through lecture and classroom activities, the course covers the following topics: by: Technologies (248) MEASURING EQUIPMENT FOCUSED PERFORMANCE IMPROVEMENT Definition of Focused Improvement How Focused Improvement is integrated with the other pillars of TPM Overall Equipment Effectiveness (OEE) Major equipment losses and methods for reducing them to zero Focused improvement implementation process Identifying opportunities to apply Focused Improvement at your plant Length: 1 day M03183A, Rev. 6 6

8 by: Technologies (248) FOCUSED IMPROVEMENT MEASURING QUICK EQUIPMENT SETUP PERFORMANCE AND CHANGEOVER WORKSHOP Quick Setup and Changeover is the key to reducing product change bottlenecks, lowering costs and improving quality. This course teaches a proven step-by-step approach for reducing setup and changeover losses and for achieving Just-In-Time (JIT) production. Upon successful completion of this course, you will be able to: Describe the benefits of reducing setup and changeover Define setup and changeover and its impact on your OEE Follow a proven approach for reducing setup and changeover in your own plant. Length: 1-2 days FOCUSED IMPROVEMENT This course covers calculation of key equipment performance metrics including: Overall Equipment Effectiveness (OEE) Mean Time Between Failures (MTBF) Mean Time To Repair (MTTR) MEASURING MEASURING EQUIPMENT PERFORMANCE EQUIPMENT PERFORMANCE Measuring equipment performance is fundamental to improving equipment performance. Length: 4 hours by: Technologies (248) M03183A, Rev. 6 7

9 by: Technologies (248) FOCUSED IMPROVEMENT MEASURING EQUIPMENT WHY-WHY PERFORMANCE ANALYSIS AUTONOMOUS MAINTENANCE AUTONOMOUS MAINTENANCE WORKSHOP This workshop teaches "Why-Why Analysis," one of the easiest methods for exploring the root cause(s) of problems. Through instruction, exercises and case studies, participants learn how to review problems, look into various problem factors, sort out their inter-relationships and identify the root causes. Upon successful completion of this course, you will be able to: Define TPM, its benefits and main elements Define Why-Why Analysis Determine when to use Why-Why Analysis Identify problems accurately Determine the root cause(s) of problems Identify ways to prevent problems from recurring Length: 1 day This course provides a foundation in TPM concepts and stresses the importance of "...keeping one's own equipment in good condition..." through activities such as inspection, lubrication, troubleshooting, minor adjustments and accuracy checks. The course includes a "hands-on" exercise at local manufacturing plant, where participants put theory into practice. Upon successful completion of this workshop, you will be able to: Define Autonomous Maintenance Promote and demonstrate the benefits of Autonomous Maintenance Identify small underlying equipment problems called abnormalities Develop operator standards for keeping equipment in "like new" condition Explain how to lead small group activities Length: 3 days M03183A, Rev. 6 8

10 AUTONOMOUS MAINTENANCE TPM BASIC TRAINING SERIES FOR SHOP FLOOR TEAMS This eight-module series is designed to enable TPM Shop Floor Teams to become fully effective through the initial stages of TPM implementation. The TPM Basic Training Series for Shop Floor Teams emphasizes shop floor and classroom activities. It is intended for use by TPM Shop Floor Teams that are beginning TPM implementation in their areas. The series includes the following eight modules: Module 1: Introduction to Small Group Activities Module 2: Data Tracking and Analysis Module 3: Why-Why Analysis Module 4: Cleaning and Inspection Module 5: Countermeasures for Sources of Contamination and Hard-to-Reach Places Module 6: Visual Management Module 7: Lubrication Module 8: Draft Standards Length: This series is presented on-site only. Each module lasts one-half day, with modules typically presented in pairs to provide a full day's instruction. Intervals of approximately two weeks are recommended between modules. The intervals allow the participants to complete assignments that contribute to the process of implementing Autonomous Maintenance. Most modules are also available individually. Contact us for more information. M03183A, Rev. 6 9

11 AUTONOMOUS MAINTENANCE A One Point Lesson is a focused, on-the-job training unit that covers a single skill or point of knowledge. This course teaches you how to apply this powerful TPM learning tool to improve employee performance for your key processes or procedures. ONE POINT LESSONS Length: 4 hours AUTONOMOUS MAINTENANCE 5S VISUAL MANAGEMENT WORKSHOP 5S and the visual workplace is one of the best tools to use when starting any operational excellence conversion such as Lean Manufacturing, Total Productive Maintenance and Total Quality control. 5S Visual Workshop combines easy to understand lecture, real-life examples, hands-on exercises and shop floor application to enable and motivate participants to apply 5S and establish a system to improve workplace communication and adherence to standards. 5S Visual Workshop covers the following topics: Definition and benefits of visual workplace and the 5S pillars Pillar I - Sort/Organize Pillar II Set/Orderliness Pillar III Shine/Cleanliness Pillar IV Standardize Pillar V Sustain/Discipline Visual Applications (displays, metrics and controls) Length: 5 days M03183A, Rev. 6 10

12 PLANNED MAINTENANCE This overview course introduces basic concepts of preventive maintenance: Definitions Benefits Roles and Responsibilities INTRODUCTION TO PREVENTIVE MAINTENANCE Length: 3 hours (248) PLANNED MAINTENANCE This course introduces the Maintenance Work Cycle that helps you to: MANAGING MAINTENANCE Increase productivity Eliminate equipment failure Control equipment maintenance costs Eliminate accidents (248) In this course, you will use an evaluation template to analyze strengths and weaknesses of your maintenance work management practices. Length: 4 hours M03183A, Rev. 6 11

13 PLANNED MAINTENANCE PREVENTIVE MAINTENANCE PLANNING & SCHEDULING This course presents a structured approach to planning and scheduling preventive maintenance activities. This course includes: Identifying total PM resources requirements Establishing load-to points Developing a PM master schedule Identifying conditions that impact PM scheduling Communicating the PM schedule Length: 1 day (248) PLANNED MAINTENANCE This six-module course provides the basic knowledge needed to implement an effective preventive maintenance program. The course includes the following six modules: Module 1: Setting the Stage PREVENTIVE MAINTENANCE IMPLEMENTATION Module 2: Define Preventive Maintenance Requirements Module 3: Validating Preventive Maintenance Requirements (248) Module 4: Planning and Scheduling a PM Inspection Program Module 5: Monitoring the PM Process and Measuring the Results Module 6: Advanced PM Tools and Autonomous Maintenance Length This course is presented on-site only. Each module lasts one day, with approximately oneweek intervals recommended between modules. The intervals allow the participants to complete assignments that contribute to the process of PM implementation. M03183A, Rev. 6 12

14 EARLY EQUIPMENT MANAGEMENT EARLY EQUIPMENT MANAGEMENT WORKSHOP This one-day course is designed to enable and motivate managers, engineers, operators, and maintenance personnel to optimize new equipment performance and minimize costs throughout the equipment life cycle. Early Equipment Management (EEM) involves all employees in equipment optimization and ensures that future purchases are cost justified, accurately specified, and properly designed and installed. EEM is essential to achieving operational excellence in any World-Class Organization. Early Equipment Management workshop covers the following topics: Definition and Benefits of EEM Equipment Life Cycle Model Calculate Equipment Life Cycle Cost Maintenance Prevention Design Attributes Develop Assessment Criteria for implementing EEM Develop Action Plan to implement EEM Length: 1 day M03183A, Rev. 6 13