Team Leader and Change Agent Level Workshop

Details of course dates are available at www.dakacademy.com

More and more organisations are recognising the power of TPM to complement and accelerate the gains from their Lean and/or Six Sigma improvement programmes. Its capability to engage production and maintenance functions in delivery of zero breakdowns is well proven. From that foundation TPM provides the route map to reduce quality defects, improve process flexibility and release management/specialist time to manage longer term/strategic business development.

Learn how to apply TPM tools to secure zero breakdowns, increase capacity and establish the foundations for year on year improvement in OEE. During this workshop, participants will systematically apply a proven combination of over 20 TPM improvement techniques to live equipment set up as simulated manufacturing process in the engineering workshop of Thames Valley University. This is one of the reasons why the workshop is spread over 3 days. The hands on TPM activity provides participants with essential experience of what it takes to apply TPM. The course material includes an electronic copy of the TPM workbook and action planing sessions to aid the transfer of lessons learned on return to the workplace. Furthermore, these activities are carried out in teams providing the opportunity for participants to understand the teamworking and leadership processes needed to deliver lasting change and the successful application of TPM techniques.

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As well as learning about underpinning concepts and implementation steps, participants will work in teams to apply TPM tools to equipment in the engineering workshop of Reading College. Here equipment is set up as a simulated production process to make the experience as near to reality as possible.
	WHO SHOULD ATTEND This workshop is designed for those who want more than an explanation of basic concepts or a TPM history lesson. It is designed for those who are looking for practical tools to engage the workforce in delivering high levels of reliability and a never ending improvement in “door to door” effectiveness. This is a course for Business leaders, TPM Champions and Facilitators and First Line Managers who want to improve the effectiveness of their operations. The course is also of value to Project Managers who have responsibility for delivering company wide improvement programmes or operational capital projects.

Workshop Materials

As mentioned above, during this workshop, participants will systematically apply a proven combination of over 20 TPM improvement techniques to a live production process. This is one of the reasons why the workshop is spread over 3 days. The practical application provides participants with essential experience to aid the transfer of lessons learned on return to the workplace. Furthermore, these activities are carried out in teams providing the opportunity for participants to understand the team working and leadership processes needed to support successful application of TPM techniques.

Workshop documentation includes a structured workbook containing detailed briefing notes for each step of the TPM improvement process. Participants work through each step, with support from the workshop leader, developing practical examples of how to apply each.

In addition to course materials, participants are provided with electronic copies of:

- The workbook so that they can use it to apply the lessons learned to equipment back in the workplace.
- General awareness presentation material that they can use to raise awareness of TPM principles and techniques.

Outline Agenda

During the morning of day one following an introduction to TPM basics, participants work in teams to identify potential improvement opportunities on live projects using TPM mapping and criticality assessment techniques. This helps participants to understand how to structure an equipment review, how to assess current standards and working practices and how to use the power of a practical OEE (Overall Equipment Effectiveness) measure to assess the value of improvement potential, set realistic and achievable improvement targets and identify practical improvement tactics to deliver that potential.

After lunch day one and day two participants continue to work in teams on mini projects where they carry out a condition appraisal and develop best practices for Asset Care, Planned Maintenance and Correct Operation. They also gain an understanding of how these activities can deliver the challenging but achievable TPM goal of zero breakdowns. From this the programme progresses to the use of Focussed Improvement as a trigger for innovation and problem prevention.
During these activities teams are guided through the selection and application of relevant focussed improvement tools covering problem observation, analysis and solution development. This includes the use of methodologies such as 5 Why’s, P-M Analysis, Visual management and foolproofing.

On Day three participants feedback their respective project improvements and action plans to each other. In this way, participants gain a first hand insight into the application of TPM toolset for up to 2 pieces of equipment.

The final session during day 3 covers the TPM master plan milestones, behavioural benchmarks and underpinning TPM systems. During this session participants are guided through the completion of a TPM audit to assess the status of their organisation. This helps them to identify areas of good practice and priorities for action. There will also be plenty of opportunity to discuss specific implementation issues and develop personal action plans to implement the lessons learned back at the workplace.