Keynote Case Studies and Special Sessions Presentations Networking





Hoshin Planning for TPM
Hoshin planning, or policy deployment, is the lean way to connect top-level strategy to specific quarterly, annual, and multi-year targets. In this management-level workshop you will learn how to use hoshin planning to execute the business case for TPM and to translate your needs assessment into a living reference map for your TPM “true north” connecting actions with metrics and your P&L. You will learn how to select the vital few strategic initiatives for your TPM transformation, specify who’s responsible for what, set targets, and define the anticipated quantitative and qualitative impacts. You’ll come away with the core knowledge to start using hoshin planning for TPM to keep your efforts manageable, accountable, scaled for success, and tied to your organization’s big picture.

Agenda at a Glance




Developing a TPM Culture
TPM is more than a program; it represents a new work culture that affects the organization from top to bottom. A TPM culture means that production and maintenance associates truly share ownership of equipment and processes. In this workshop you’ll learn the principles and practices that will help ensure your TPM initiatives grow strong roots to support true cultural change. Learn these critical elements: how to set up a system for all associates to continually develop the essential technical and social skills to support TPM; how to evaluate training effectiveness; and how use leaderships strategies at all levels to help move from “explicit” or formal knowledge to the “tacit” or ingrained knowledge that feeds daily improvement.

Agenda at a Glance




Collaborating for Excellence in Basic Equipment Care
When operators and maintenance staff collaborate on equipment and process care, 40% to 60% of unplanned downtime can be eliminated. In this engaging workshop, you’ll learn the principles of setting up a system of operator-based care through the seven steps of Autonomous Maintenance (AM). AM is not autonomous “fix and repair.” It’s a culture in which all operators know what to look, listen, feel, and smell for, so that they can work in tandem with maintenance to properly operate and maintain equipment and eliminate abnormalities and losses. Discover how to put the critical TPM Pillar of Autonomous Maintenance to work effectively in your company.

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Building Your Master Plan
No matter where you are in developing your TPM initiative, you need a master plan to guide the detailed work of your ongoing transformation. In this workshop you will learn the essential skills to build a robust master plan for your rollout, and create the framework for your organization’s customized plan for success. A reliable roadmap for change moves from pull and readiness stages through management awareness, value stream analysis, site plan design, training, executing the eight pillars of TPM, auditing progress, and ongoing sustainment. But your plan must be “situational,” that is, specifically customized for your organization’s circumstances and industry environment. You will leave this session with an outline of a master plan for your organization.

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Using Mistake-Proofing to Eliminate Defects
Processes and equipment that are designed to make it easy to do the right thing the right way eliminate errors before they produce defects. In this key tool workshop we will demonstrate a scientific method to signal, avoid, and control defects and eliminate source errors. You will learn how to examine processes and determine the conditions that lead to errors and defects, and find out how to use mistake-proofing (poka-yoke) devices and/or interventions to inspect for errors and defective operating conditions. Mistake-proofing techniques also help you identify potential missteps in the application of maintenance practices, and then take the necessary steps to avoid them.

Agenda at a Glance




Sustainment: Creating Countermeasures for “TPM Failure Modes”
Every TPM transformation will run into obstacles that can impede your progress. In this interactive workshop you will learn the typical social and technical “failure modes” of TPM initiatives and prepare yourself to avoid them, or proactively determine appropriate countermeasures even before issues arise. You’ll also learn best practices that will help you and others respond quickly to unanticipated issues. You’ll discover how to prevent stumbling blocks from derailing your efforts and sending you back to square one. You’ll also learn how these failure modes, when handled properly, can actually strengthen the development of your TPM culture over the long haul.

Agenda at a Glance




Identifying and Eliminating Major Losses
When you systematically identify and eliminate equipment-specific losses with a “take-no-prisoners” attitude you can achieve optimal effectiveness in your production operations. Find out how Focused Improvement can work in tandem with Autonomous Maintenance and other TPM pillars to eliminate and control losses. In this jam-packed workshop we will teach you how to use value stream analysis to pinpoint the critical weak spots on your production line. You will learn the true significance of Overall Equipment Effectiveness (OEE), and the best methods for reporting data. And you’ll discover how to use the Focused Improvement Diagram to document, monitor, and trend equipment-related losses, and how to create a process for determining the remedial actions needed to eliminate chronic and sporadic losses. With a good understanding of Focused Improvement you will be on your way to mapping your TPM launch points, optimizing OEE, and getting the return on investment you need from your TPM efforts.

Agenda at a Glance




Innovation and Design for TPM
Early Equipment Management and 3P are processes that lead to the discovery and proving of next generation lean equipment designs. Think…“changeover so rapid that it becomes transparent from a capacity perspective.” Think…“hitting the reset button on reliability.” Think…“zero quality loss, and a life-cycle cost that changes the game.” While EEM is deployed from new equipment design, the 3P methodology is effectively deployed at both the new equipment design stage and when addressing chronic equipment design deficiencies in existing equipment. In this session, hear details surrounding EEM/3P projects that focused on equipment and process redesign. You’ll gain an understanding of the power of 3P and EEM and the ROI that can be achieved when employing these techniques.

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A3 and other Problem-Solving Approaches
Ever had to fix a problem more than once? That happens when the root cause hasn’t been addressed. This workshop explores the how-to’s of problem-solving methodologies that enable process owners and teams to get from symptoms to root cause in a variety of circumstances. From the deceptively simple “5 Whys” to the comprehensive A3 process, you will learn reliable, systematic ways to move a current-state condition, problem, or improvement target to future state through a process of diagnosing symptoms, generating ideas, and driving to root cause. With effective problem-solving skills, you’ll be able to take full advantage of your problem “opportunities.” Learn how to invest your time and energy in fixing problems correctly the first time, so you’ll never have to “solve” them twice.

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Transitioning from Reactive to Proactive Maintenance
When you advance from reactive to proactive maintenance, you get ahead of equipment and process failures before the conditions that cause them ever begin. Learn how to target the root causes of failures through the Maintenance Improvement TPM pillar. As part of the process, maintenance personnel reveal equipment weaknesses through breakdown analysis. They also improve operability, maintainability, and service life by modifying equipment and managing replacement parts. This workshop will cover the activities embedded in the four maintenance techniques—preventative, corrective, prevention, and breakdown—and how and when to use them. You’ll learn the essentials of stores management, proper maintenance planning and scheduling, how to establish a maintenance scorecard, and the most effective way to use CMMS.

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Leader Standard Work
The overall success of your TPM initiative depends on what happens in the gemba (the workplace) every single day. That, in turn, depends on your leadership team’s collective ability to lead the change process. In this workshop we teach you the fundamentals of developing leader standard work routines that aligns leaders at every level to maintain progress in the gemba. You’ll learn the key elements of leader standard work for TPM at different management levels, how to design and schedule effective gemba walks, and how leader standard work can help you address the most common transformational issues and incorporate remedial corrective-actions and countermeasures.

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Integrating Quality, Six-Sigma, and TPM
Zero losses –› zero defects –› perfect quality and performance. How could this formula advance your operation, your career, your company? Maintaining equipment in perfect condition to produce perfect results is the essence of the Quality Maintenance pillar of TPM. In this in-depth workshop, you will learn how to use six sigma techniques to identify the conditions that affect product quality, establish baselines for those conditions, and create a process to monitor them. We’ll explore how six sigma integrates with TPM to help you achieve total process control. Sharpen your ability to achieve zero breakdowns and zero defects with minimum maintenance cost by learning how to apply these powerful methodologies in tandem.

Agenda at a Glance


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