Reliability Centered Maintenance (RCM) and Total Productive Maintenance (TPM) - 2 Day Presentation

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BENEFITS OF DOCUMENT

1. Improve reliability of plant & equipment

2. Measure the machine performance losses and understand better

3. Introduce autonomous maintenance

DOCUMENT DESCRIPTION

Reliability Centered Maintenance and Total Productive Maintenance presentation is intended to help as a 2-day workshop material for Operations and Maintenance personnel.
This presentation consists of over 200 slides and comprises of the following:

Group Activity - Define Maintenance Excellence
Maintenance Excellence - Activity
What is RCM?
Objective & goal of RCM
Techniques employed by RCM
Primary RCM Principles
Types of Maintenance Tasks
RCM Considerations, Applicability + Benefits
Steps in RCM Implementation
TPM vision, definition, origins, principles
8 Pillars of TPM
TPM Self-Assessment
Autonomous maintenance
Equipment & Process Improvement
Equipment Losses, Manpower & Material Losses
OEE - what it is & Calculations
Activity OEE Calculation
Other pillars of TPM
TPM Implementation - 12 steps
Benefits & OEE Tracker
Proactive Maintenance Analysis
Liaison with Ops, Communicating OEE,
Group Activity - OEE Communication/Importance
Ops. Skills, Cleanliness,
Monitoring - Gauges, Lubrication, Contamination, Vibration, One point Lesson
Activity - Maintenance / Operations
Analysis of Maintenance History, MTBF and its calculation
Activity - MTBF Calculation
Improving Equipment performance
FMEA, Types, Calculating RPN
Activity
HAZOP Hazard and Operability Analysis
Condition Monitoring Analysis / Predictive Maintenance / Condition Based Monitoring
Vibration Monitoring, Oil sampling & testing, Thermography, Types, Ultrasonics, Human Senses and Condition Monitoring Strategy
Activity -
Maintenance Excellence
Activity - Why equipment fails?
3 Contributors, Lubrication, Vibration and contamination
Proactive Maintenance - 6 big losses, OEE
Prioritization of equipment problems
Focused equipment & process Improvement
Cleaning, Inspection, Equipment tagging, CI
Maintenance Strategies - TPM or RCM? Or Other?
Activity: TPM vs RCM
Maintenance Excellence - making the difference
Activity: Using our senses
Eliminating lubrication issues, frequency, type, Mistake proofing, Standards, Visual management, Automation, daily Checks
Activity - Improving Lubrication Practices
Vibration Practices and improvement
Activity - Reducing Vibration
Contamination
Activity - Reducing Contamination
Operator Involvement - Check lists, visual controls

Also included with this document is a bonus zip of 41 Lean documents (includes templates, case studies, articles, posters, charts, and more).