MTN 002 – Total Productive Maintenance

MTN 002 – Total Productive Maintenance

Teachers
Dr. Mohd Shafarudin
Category:
In-House Programs/ Maintenance/ Technical & Engineering/
TOTAL PRODUCTIVE MAINTANANCE

Duration: 2 Days
Lectures: InHouse
Certificate of Completion

INTRODUCTION

Organization’s materials cost constitutes the major cost for the production of their products. Materials cost consist of Ordering Cost, Receiving Cost, Holding Cost, Reject Cost and  Purchase Cost. We need to balance or optimize this cost. This course is solely focus on Materials Management.

Objective

  • Understanding the roles of a Purchaser, How to initiate a Purchase and factors to consider.
  • Vendor selection criteria
  • To develop Ordering Parameters / Inventory control techniques
  • JIT and Kanban Implementation
  • To understand 80/20 principles in life, manufacturing and Store.
  • To conduct ABC Inventory Classification
  • To calculate Average Inventory Estimation
  • To calculate Statistical Safety Stock.
  • To Compute Economic Ordering Quantity (EOQ)
  • To Calculate Total Planned Average Inventory
  • To improve Inventory Turns.
  • To conduct Cycle Counting and improve Inventory Accuracy.
  • To analyze Demand Variation and Lead Time Impact on Inventories.
  • To initiate Supplier Stocking Programs
  • To drive for Consignment Systems programs
  • To generate Materials Aging Report and Dispositions.
  • To drive for Short Span and Lead Time.
  • Types of Forecasting – 3pt Moving Average and 3pt weighted moving average

Who should attend?

  • Factory Manager / Production Manager / Executive / Supervisor
  • Materials Manager/Executive/Officer
  • Warehouse/Store Manager / Executive/ Supervisor
  • Production & Materials Planner / Manager
  • Purchasing Manager, Executive, Buyer

Methodology

Lecture, Workshop Activities, Discussion & Calculations.

Note: Soft Tools will be given away free. Participants are encouraged to bring thumb drive or pen drive to copy  the tools for application.

CURRICULUM

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Day One

  • What is Productivity?
  • Employees Role

  • Customer’s Priorities
  • Organization’s Priorities
  • Reasons for Operation Stoppages
  • Cost of Operation Stops
  • Sources of Quality Defects
  • Cost of Bad Quality

  • What is Maintenance?
  • Types of Maintenance
  • Good Maintenance Practice

  • Productivity and Maintenance Performance
  • Impact of Poorly Maintained Equipment
  • Impact on Meeting Customer Demand
  • Major Causes of Equipment Breakdown
  • Poor Environment Conditions
  • Preventive Maintenance as Machine Health Management

  • Productivity and Maintenance Performance
  • Impact of Poorly Maintained Equipment
  • Impact on Meeting Customer Demand
  • Major Causes of Equipment Breakdown
  • Poor Environment Conditions
  • Preventive Maintenance as Machine Health Management

Day Two

  • History of TPM
  • What is TPM?
  • Why TPM?
  • Definition of TPM
  • What Makes TPM Different?
  • Inculcating New Beliefs

  • TQM vs. TPM
  • Similarities
  • Differences

  • Productivity and Quality
  • Cost, Delivery and Multi-Skill

  • Overall Equipment Effectiveness
  • TPM Introduction Steps
  • Organization Structure for TPM Implementation

  • Pillar 1: 5S
  • Pillar 2: Autonomous Maintenance
  • Pillar 3: Kaizen
  • Pillar 4: Planned Maintenance
  • Pillar 5: Quality Maintenance
  • Pillar 6: Training
  • Pillar 7: Office TPM
  • Pillar 8: Safety, Health and Environment

About Instructors

Dr. Mohd Shafarudin
- Boilers - The Heart of Production - Scada and Automation System - Principles of Preventive Maintenance