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ClarityVM Workshops

Total Productive Maintenance

Following on from Value Stream Mapping workshops, this very often identifies the need to improve equipment availability and increase capacity across the site.

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TPM (Total Productive Maintenance) is a process designed to maintain equipment to maximise its avaialbility and thus reduce downtime or LOST time for procesess dependent equipment.  Maintaining equipment helps to achieve the goal of: Zero Accidents, Zero Defects, Zero Breakdowns, Zero Waste

By keeping your equipment reliable, costs are reduced, quality is improved and safety is built into the process, thus increasing your competitive edge, ie increase the On Time In Full (OTIF) measure. Traditional maintenance systems rely just on equipment OEM service level agreements to attend annual service schedules or call outs to attend equipment breakdowns (lost time). Along with In-house preventative maintenance plans, this is how availably is achieved.

What if you could have a third system which incorporates the actual operator of the equipment to become your first line of defence to breakdowns. By utilising basic daily checks to confirm the machine or equipment, we can now utilise a new set of sensory detection, ie being proactive to breakdowns rather than traditional reactive modes.

We will also introduce the client to OEE (Overall Equipment Effectiveness) which acts a major kpi for improvement.

We’ll explore what TPM is and the historic background. Why we to use it when equipment is used in the process. We will consider the benefits of this low-cost system. The need to identify TPM with the business, to ensure that standards and learning are being employed in a consistent way. How best to introduce the system into daily operations by utilising local / OEM equipment knowledge and developing standard daily checks.

Morning Session:

  • TPM Overview / refresh
  • Walk the process – All
  • Understand / analyse breakdown date
  • Understand OEE
  • Overview of the System and worked examples

Afternoon Session:

  • Identify key Daily / Weekly checks
  • Create simple audit systems and issues management
  • Create TPM (SoP) – team
  • Design supporting TPM Visual Management Board
  • Example TPM Board (1200 x 1800) with associated documents
  • Tee Card System (board 900 x 1200) with Tee Cards for managing the process
  • Yellow Tags – breakdown reporting
  • Handouts of Presentation

Team members will finish their workshop with an understanding of TPM basics and have enough knowledge to:

  • Understand TPM
  • Understand how to create a Standard Operating Process for TPM
  • How issues are reported / managed
  • How the system drives the sustainment of TPM
  • What kpi to introduce to demonstrate control

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Discover how Clarity workshops ignite business success. Just fill in the form below and we will contact you to discuss a booking.

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The work Clarity has done for our site has revolutionised the way we operate our lines; staff are actually communicating with one another and we’re all using the data and hard facts shown in the KPI boards to make decisions.

Paul Mann - Hub Operations Manager, DPD

Working with Clarity as a partnership really works for me; you’re open to different challenges and the team that I work with have been really responsive, they’ve also come up with some ideas which I’d not thought of. I see myself as an expert in visual management but you guys have still managed to teach me some things.

Craig Wilkinson – Network Rail

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Steve Lomax – Crown Paints

Clarity’s solutions have played an important part in our visualisation success in Network Rail’s LNE, and are essential to the programme. Clarity supported us to reduce our Operations and Maintenance expenditure from £180,000,000 to £166,000,000. That’s a £14,000,000 saving! We also saw a 20% reduction on workforce and irregular working accidents and general performance across operators on the East Coast Mainline has improved.

Phil Verster, Managing Director of LNE

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