Make TPM Lean and Digital

Delivering the Gains 

An important Leadership role is envisioning how the enhanced connectivity that  Smart Tech delivers, can change the way the business operates.   For example, before digitisation, the daily reporting routine in one food a drink manufacturer involved collation of information from 10 separate systems.  That took up 90 minutes of First Line Manager activity per shift. 

Digitisation removed the need to do that and changed the daily priority for them from collecting data to using that data to develop the insight to improve future performance.  It also changed the nature of the conversations between first line managers and their teams from problem solving to problem prevention improving engagement and encouraging a proactive improvement culture.

Workforce Engagement

This course sets out how to deliver the gains from investment in Smart Technology by engaging users with activities to:

• Encourage curiosity about how the new digital ecosystem can remove pain points, reduce waste and improve added value,
• Convert ideas into of practical improvements whilst running the business,
• Transition to new ways of working that increase customer value and support growth.

What Lean TPM Adds 

The goal of TPM is the never ending improvement in equipment effectiveness through front line improvement teams. It provides a practical road map to stabilise and optimise operations.  That can raise capacity, reduce costs, improve operational safety and reduce quality defects.  

The value of Lean thinking its ability to systematically improve workflow to achieve all of the above with less effort.

Together Lean and TPM these provide a roadmap to reduce waste and release the full potential of manufacturing plant and processes. 

Combining that with the enhanced connectivity of Digitisation and Smart Technology, accelerates the pace of systematic improvement.

What you will learn

The course raises awareness of the Smart Technology Landscape to provide an overview of what is available as well as common pitfalls to avoid.  The content includes practical exercises leading to completion of a diagnostic workbook to identify strengths and priorities for improvement to support the successful introduction of Smart Technology and Digitisation projects.  That includes content to:

• Understand the Smart Technology Landscape,
• Identify the impact that Smart Technology can have on the current way of working and business model,
• Recognise where that technology can enhance:
  • Ability to succeed in existing markets,
  • Provide a platform to progress into new markets
  • Create new markets and set the customer agenda,
•  How to selecting the Smart Technology project to achieve the best outcome.

That introduces delegates to how to:

• Recognise and fix legacy system weaknesses,
• Use data to systemise and enhance process control and workflows across the Plan, Source, Make Deliver value chain,
• Establish a Smart Technology Roadmap programme as a vehicle to deliver profitability and growth.

Raise Awareness of

• The advanced technology landscape, potential gains for your company and how to deliver them.
• The Digitisation roadmap milestones. 

Understand

The synergy released by combining Digitisation, TPM and Lean improvement frameworks.

Know how

The Lean TPM Digital road map guides the creation of practical digital "Use cases" that:

• Link together untapped data.
• Surface and resolve legacy system weaknesses.
• Deliver enhanced real time workflow performance and customer value.
• Capture and deploy lessons learned.

Be able to

• Integrate Lean, TPM and Digitisation into a forward improvement programme that builds on existing good practices and accelerate progress towards industry leading performance as part of the day to day routine.

Who should attend?

The workshop content is designed for those faced with the challenge of tapping into the potential gains of advanced technology.  That includes:

• Business Sponsors,
• Operational Managers and Team Leaders
• IT/OT Specialists
• Project Mangers
• Manufacturing Engineers
• Change Agents and CI Facilitators

The Advanced Technology Landscape Winning Tactics and Pitfalls

• Diagnostic review
• Where the gains come from
• Common pitfalls.
• Delivering the gains you need.

OEE Desk Top Simulation

• OEE improvement strategues
• Defining the improvement glide path.
• Tapping into Performance and Cultural Drivers.

Digitisation Improvement Plan 

• The SmartTech improvement cycle
• Creating Digital Dashboards
  • Plant Asset Care
  • Real Time workflows
  • Analysis, Machine Learning and AI.
  • Use Case, Microsystems and Systems Modelling.

The SmartTech Improvement Cycle

• Automating Local Leader daily/weekly PDCA cycles
• IT/OT/Operations cross functional improvement teams improvement process.
• Automating Senior Leader Monthly/Quarterly PDCA cycles

Where to Start

• Diagnostic and Readiness Review
• Piloting the LeanTPM Digital approach
• Scaling up successful Use Cases.

Your (Evolving) Digital Company Road Map

• Defining a realistic and achievable 12 Month Outcome.
• 90 day forward plan. 

Review of the Workshop

• Benefits, Concerns, Q&A

Dennis McCarthy- DAK Consulting

Dennis began his career as an industrial engineer progressing into general management and director level roles.  As a consultant he has helped well- respected and award winning organisations to accelerate the pace of improvement.  This includes support for internal teams meeting challenges ranging from underperforming assets to company-wide multi-site transformation programmes in Europe, Australia, USA, India and China.