Make TPM Lean and Digital 3 Day Course

This is a course for all those facing the challenge of adapting to the changing landscape of manufacturing in a digitised environment. 

• Manufacturing improvement champions,
• Plant Managers,
• Team Leaders,
• Production supervisors,
• Maintenance Managers,
• Technicians,
• Engineers,
• Manufacturing Improvement Leaders.

Learn

• What it takes to drive Total Productive Manufacturing (TPM) and Lean Thinking using our desktop OEE simulation.

Know

• How real time data analysis can improve insights into causal factors, speed up problem resolution to optimise the end to end plan, source, make deliver manufacturing process.

Understand

• Where Connected Worker and real time Dynamic Scheduling can deliver higher levels of reliability, accelerate the pace of continuous improvement and adapt to deliver gains from evolving technologies.

Be able to

• Develop a realistic and achievable plan to transfer lessons learned back to the workplace.

Day 1: Make TPM Lean and Digital Overview

• Introduction to TPM and Lean Thinking
  • OEE (Overall Equipment Effectiveness) desk top simulation exercise
• The Smart Technology landscape, where the gains come from and how to adapt to advancing technology developments.
• The connected worker and systematic improvement:
  • Loss Tree analysis/cost modelling,
  • Dynamic Scheduling,
  • Digital Twin glide path development.

Transfer to the selected production shop floor assets to perform a comprehensive assessment of manufacturing processes.

Work in small teams following a structured workbook with briefing notes covering:

Understanding  the Asset

• Transactional Value Stream Map, Asset description and Criticality Assessment to collate operational knowledge re causal factors, performance drivers and reliability pain point,
• Definition of notification flags to sustain basic conditions and systematic improvement,
• Tracking true OEE levels and setting realistic and achievable 12 month improvement targets.

Day 2: Analysing Plant and Workflow Effectiveness Drivers

Delegates continue to work in small Teams on the shop floor projects covering: 

• Condition Appraisal and Refurbishment Plan.  This includes setting standards for basic conditions and the identification of accelerated wear.
• Development of a PFEA (Plan for every asset) covering Best practice asset care and correct operation.  That includes identification of cross functional accountabilities and the integration of asset care with operating best practice.

• Standardisation covering:
  • Work categorisation to reduce the risk of human error and enhance best practice compliance,
  • Dynamic Scheduling and skill matching,
  • Workplace organisation standards including local access to data.
• Learning plans
  • to resolve skill gaps,
  • Over the shoulder support,
  • Team based capability development.
• The Connected Worker
  • Creating a Digital Backbone,
  • Data Management,
  • Identification of analysis priorities, pain points and technology selection.

 Day 3: Creating Digital Centres of Excellence

• Digital Ecosystem: Sustaining Basic Conditions
  • Systemise "Normal Conditions" using condition based "Notifications" and trouble shooting algorithms plus over the shoulder support,
  • Capture of lessons learned, sharing insights and accelerated scale-up.
• Digital Ecosystem: Systematic Improvement
  • Data analytics as part of PDCA cycle to interpret data patterns, trends, and causal factors to Prevent unplanned downtime, extend component lifespan, optimise processes.
• Mini project feedback session
• Digital Ecosystem: Modelling and App Development
  • Plan, Source, Make and Deliver process improvement.
  • "Use Case"  models and microservice applications to automate routines and support decision making,
  • "Improvement Leader Networks" to engage the organisation with adopting smart technology.
• Developing Action Plans
  
  • Transferring lessons learned on the course to the workplace.

The workshop will be led by Dennis McCarthy. 

Dennis has supported TPM, Lean Thinking and Continuous improvement programmes ranging in size from small single site applications to company-wide multi-site transformation programmes in Europe, USA, India and China.  This includes support for well respected and award winning organisations such as 3M, Heineken, Pirelli and Rolls Royce. He has pioneered the use of Digitisation to accelerate the pace of improvement and the use of TPM and Lean roadmaps to guide the delivery of the gains from smart technology and digitisation.