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TPM Experience

The

A Four Day Conference focused on A Strategic Approach to the Implementation of Total Productive Maintenance

June 22-25, 2009 · Gaylord Opryland Hotel · Nashville, TN

www.totalproductivemaintenanceconference.com

The

TPM Experience

A Systematic Approach to the Implementation of Total Productive Maintenance

More than a conference, it is a four-day interactive learning experience designed to help you uncover the hidden opportunity in your maintenance operation that will save you money NOW and provide long-term economic benefits for decades to come.

June 22-25, 2009 · Gaylord Opryland Hotel · Nashville, TN

This four-day intensive learning event will teach you:

· equipment reliability tools and techniques you can immediately use · how the implementation of TPM can help to reduce cost NOW · how to implement TPM in a simple, cost effective manner · how to accelerate the implementation of TPM (it doesn't have to take years!) · how and when to apply each of the pillars of TPM (they don't have to be done in sequence!) · how and when to apply predictive technologies as part of an overall reliability program · how to build people skills in order to maintain the effort

About the Conference

When sitting down to plan this year's TPM conference there was a lot for us to consider. There is no escaping it, times are tough. Economic pressures are shrinking budgets and leaving organizations looking for ways to cut costs without cutting the heart out of their improvement programs. It is a balancing act the likes of which we have not seen before. Recognizing that these are not ordinary times, we designed the conference to deliver an immediate return on your investment. Organized into four tracks this event will teach you how to implement Total Productive Maintenance in a simple, accelerated and cost effective manner. Understand the pillars of TPM and how and when you implement them to get the biggest return in the shortest time. Discover the proper use of predictive technologies as part of an overall equipment reliability program, and learn what is necessary to build strong, effective teams to support the overall effort.

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www.totalproductivemaintenanceconference.com

Organized into four tracks:

The Pillars of TPM

1

Predictive Technologies

2

Support Tools

3

Culture

4

This event features both four-hour in-depth workshops and one-hour case studies. Choose from over 30 sessions and build a curriculum that best suits your individual needs

TPM Practitioner Certificate

Participation in the entire event will provide you with a well-rounded educational experience. In the workshops you will gain a solid understanding of the equipment reliability improvement methodologies--what they are and how and when to employ them. The case study sessions bring these methodologies to life--hear real people talk about real implementations. Learn how your peers are using these techniques, the obstacles they have encountered and the solutions they found to reach success. This powerful combination positions you to return home and immediately put your knowledge to use as part of your equipment reliability efforts. Participants who enroll in the educational events Monday through Thursday will earn the TPM Practitioner Certificate.

Bring your team to the conference and receive a FREE registration!

Recognizing that budgets are tight, we are offering special group pricing--for every four attendees you send, you will get the fifth attendee FREE! (Groups of 3 individuals will receive a 10% discount off each registration fee). If you are interested in holding a corporate Lean or TPM team meeting as part of this conference we can offer assistance with your meeting space needs and logistics. For more information call (203) 225-0451 or 800-966-5423.

Build a Maintenance Profit Center

Economic pressures are forcing organizations to think lean-er and one area that is ripe for improvement is the maintenance function. Organizations have put tremendous effort into their Lean initiatives yet continue to overlook the enormous economic benefits that come from having reliable equipment. Proactive maintenance means consistent, reliable equipment which can substantially reduce costs and generate significant additional income by increasing overall capacity. Join us in Nashville and learn how to turn your maintenance operation from a cost center to a profit center.

Productivity Inc. 4 Armstrong Road, 3rd Floor, Shelton, CT 06484 www.productivityinc.com 1-800-966-5423 or (203) 225-0451 Fax: (203) 225-0771

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CONFERENCE AGENDA

MONDAY, JUNE 22, 2009

7:30am-7:45am Opening Remarks, Productivity Inc.

(tentative, subject to change, check website for most up-to-date schedule)

TRACK 1 TPM PILLARS

8:00am-12:00pm Workshops 12:00pm-1:00pm 1:00pm-5:00pm Workshops A1 Introduction to Total Productive Maintenance Luncheon B1 Autonomous Maintenance

TRACK 2 PREDICTIVE TECHNOLOGIES

A2 Predictive Maintenance Technologies: Overview and Business Benefits

TRACK 3 SUPPORT TOOLS

A3 Quick Changeover

TRACK 4 CULTURE

A4 TPM Tactical Planning

B2 Vibration Analysis

B3 Problem Solving Using CEDAC

B4 Coordinating & Leading the TPM Effort

TUESDAY, JUNE 23, 2009

7:30am-7:45am Daily Remarks, Productivity Inc.

TRACK 1 TPM PILLARS

8:00am-12:00pm Workshops 12:00pm-1:00pm 1:00pm-5:00pm Workshops C1 Planned Maintenance Luncheon D1 The Pillar of Training and Skills Development

TRACK 2 PREDICTIVE TECHNOLOGIES

C2 Oil Analysis and Lubrication Program Management D2 Wireless and Continuous Vibration Monitoring

TRACK 3 SUPPORT TOOLS

C3 TPM Implementation Measurement & Accountability D3 Office TPM and Admin Systems

TRACK 4 CULTURE

C4 Supervisor Training

D4 Empowering the Workforce

WEDNESDAY, JUNE 24, 2009

7:30am-8:30am Daily Remarks, Productivity Inc. General Session: How to Create a Continuous Improvement Culture, Milliken & Company E1 Case Study: TPM Deployment in a World Class Environment Genentech, Inc. F1 Case Study: Operational Ownership Dr. Reddy's Laboratories Louisiana, LLC G1 Case Study: Recruit, Train, and Assess Your Maintenance Organization of Tomorrow CenTec, Inc. Luncheon E2 Case Study: Lean and TPM in Harmony Milliken & Company F2 Case Study: Recipe for Success: Driving for Results Metroparks of the Toledo Area G2 Case Study: Embedding 5S Visual in the Culture for TPM Kaiser Aluminum E3 Case Study: Business Results with TPM-- Winning the JIPM Excellence Award Sun Products Corporation F3 Case Study: Green TPM: Environment and Safety Productivity Inc. G3 Case Study: Early Equipment Management/ Maintenance Prevention Design Productivity Inc.

8:45am-9:45am Case Studies 10:00am-11:00am Case Studies 11:15am-12:15pm Case Studies

12:15pm-1:00pm

TRACK 1 TPM PILLARS

1:00pm-5:00pm Workshops H1 Focused Improvement

TRACK 2 PREDICTIVE TECHNOLOGIES

H2 Laser Alignment and Field Balancing

TRACK 3 SUPPORT TOOLS

H3 5S / Visual Workplace

TRACK 4 CULTURE

H4 Facilitator Training

THURSDAY, JUNE 25, 2009

7:30am-745am Daily Remarks, Productivity Inc.

TRACK 1 TPM PILLARS

8:00am-12:00pm Workshops 12:00pm-12:30pm J1 Quality Maintenance Closing Session

TRACK 2 PREDICTIVE TECHNOLOGIES

J2 Infrared and Ultrasonic Analysis

TRACK 3 SUPPORT TOOLS

J3 Stores Management

TRACK 4 CULTURE

J4 Team Dynamics and Conflict Resolution

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www.totalproductivemaintenanceconference.com

The TPM Experience: Workshop Descriptions

The Pillars of TPM

1

Predictive Technologies

2

Support Tools

3

Culture

4

THE PILLARS OF TPM

Today's maintenance leaders are finding the implementation of individual maintenance improvement techniques can only

go so far in the improvement of equipment reliability. They are recognizing that in order to achieve sustainable improvements over the long term their improvement initiative must be comprised of linked methods that build on one another. The Pillars of TPM, when used as a whole, provide the strategic approach that is missing from many maintenance improvement programs. The modules included in the Pillars of TPM track have been designed to provide you with detailed information on TPM's five core pillars and how the pillars relate to each other to create a natural synergy that when implemented will provide an immediate return on your TPM investment.

A1 Introduction to Total Productive Maintenance

Monday, June 22, 8:00am-12:00pm

This module will carefully explain each of the basic TPM Pillars, how they relate to each other to create a natural synergy and how they can result in an immediate return of the TPM investment when properly utilized in today's maintenance and manufacturing workplace. Actual case studies will be explored to show the rates of sustained improvements and to show the relationship between TPM and the roots of Lean Manufacturing.

D1 The Pillar of Training and Skills Development

Tuesday, June 23, 1:00pm-5:00pm

This often overlooked Pillar of TPM usually gets put aside because conventional wisdom tells us each of the other TPM pillars require training, therefore we must be performing the Training and Skills pillar. This workshop will show how having a specific focus on the Training and Skills pillar can enhance your training efforts and reduce training costs at the same time. Attendees will learn tools and techniques that enhance your training effectiveness in both hard and soft skills found within the TPM effort.

Monday, June 22, 1:00pm-5:00pm

B1 Autonomous Maintenance

When properly implemented, Autonomous Maintenance can eliminate the causes of 40-60% of unplanned downtime. In this workshop learn the seven steps of implementation, how to transform the relationship between operators and maintenance and how to implement operator-based maintenance activities that contribute to overall equipment effectiveness.

H1 Focused Improvement

Wednesday, June 24, 1:00pm-5:00pm

Focused Improvement is one of the original pillars of TPM. In contrast with autonomous maintenance, which is intended to prevent accelerated deterioration of equipment components, Focused Improvement addresses specific equipment-related losses that reduce Overall Equipment Effectiveness (OEE). The goal of Focused Improvement is to maximize OEE, processes and facility operations through uncompromising elimination of losses and improvement of performance. Participants will learn how to organize cross-functional teams and teach them to use the Focused Improvement Diagram which is a visual systematic approach to Define-Measure-Analyze-Improve-Control.

C1 Planned Maintenance

Tuesday, June 23, 8:00am-12:00pm

Moving from a reactive maintenance organization to a proactive maintenance organization requires constant improvement in the way the maintenance process is managed. A key element of any proactive maintenance organization is its ability to properly plan and schedule repairs and PMs. In this four-hour session we will review the Maintenance Pillar of TPM, present the basics of a good maintenance planning & scheduling process, and introduce metrics that will help justify the program.

J1 Quality Maintenance

Thursday, June 25. 8:00am-12:00pm

The overall goal of the Quality Maintenance Pillar of TPM is to maintain your equipment in perfect condition in order to produce a perfect product. The Quality Maintenance pillar of TPM focuses on establishing equipment conditions with the goal of avoiding quality defects. To accomplish this, the Quality Maintenance Pillar uses the tools of Six Sigma to identify conditions that affect quality, establish a baseline for those conditions, and to create a process for periodic monitoring of those conditions. This workshop explores the integration of TPM and the tools of Six Sigma to provide a well-ordered approach for acquiring total process control. Applying both of these methodologies in tandem presents today's most powerful means of achieving your equipment performance goals of "zero breakdown" and "zero defects" with minimum maintenance costs. Note--this module requires participants to have a working knowledge of TPM and Six Sigma.

THIS CONFERENCE CONSISTENTLY RATES OVER 90% ATTENDEE SATISFACTION!!

Great hands-on learning experience!

Jason Barber, Premium Waters, Inc.

Productivity Inc. 4 Armstrong Road, 3rd Floor, Shelton, CT 06484 www.productivityinc.com 1-800-966-5423 or (203) 225-0451 Fax: (203) 225-0771

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The TPM Experience: Workshop Descriptions

The Pillars of TPM

1

Predictive Technologies

2

Support Tools

3

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PREDICTIVE MAINTENANCE TECHNOLOGIES

Culture

4

A well-balanced predictive technologies effort should be an integral part of your overall equipment reliability program.

But what predictive technologies are right for your facility? The modules in the Predictive Technologies track breakdown the predictive technologies--both traditional and emerging--and show you how and where they should be applied for the biggest return.

A2 Predictive Maintenance Technologies: Overview and Business Benefits

Monday, June 22, 8:00am-12:00pm

Implementing an integrated multi-technology Predictive Maintenance Program, PdM, can be a critical step toward achieving your plant's true potential. Well implemented PdM programs have been proven to reduce maintenance costs and increase reliability of production assets. This session will introduce predictive technologies by: · Reviewing cases studies and benefits of PdM implementations at several types of industries, · Providing an overview of common PdM technologies such as vibration, motor current, infrared, and oil analysis, · Discussing the relationship between various maintenance strategies such as PdM, preventive, proactive, and corrective maintenance, · Introducing machinery wear mechanisms and failure progression and linking to the various PdM technologies, · Providing strategies for successful PdM program design and implementation, and · Presenting the newest technologies for PdM automation and integration into existing plant systems The Predictive Technology sessions that follow (B2, C2, D2, H2, J2) will build on this material and provide a detailed discussion and presentation of each technology.

identify the root causes of failure. This session will demonstrate the inspection process, data collection, analysis and reporting for the most common problems, as well as the technology theory and approach to setup a well-run program.

D2 Wireless and Continuous Vibration Monitoring

Tuesday, June 23, 1:00pm-5:00pm

In the emerging field of wireless technology, predictive maintenance programs have found a significant benefit in being able to acquire accurate vibration monitoring in hard-to-reach locations using wireless transmitters. Highly reliable, self-organizing wireless networks ensure reliable data from a greater number of locations or even cost-prohibitive locations.Continuous real-time monitoring of your most critical assets is necessary to ensure production schedules are met. Steam turbine generators, gas turbines, boiler feed pumps and compressors are examples of plant assets that can fail unexpectedly and bring down the entire plant. Knowing the condition of these assets and the criticality of developing faults allows you to determine--on your schedule--when repairs can be made. This workshop will review these components and how you can implement wireless monitoring in your own facility.

H2 Laser Alignment and Field Balancing

Wednesday, June 24, 1:00pm-5:00pm

Laser alignment and field balancing can extend the life of your rotating machinery. Imbalance and misalignment are very common faults identified using vibration analysis. Sophisticated but easy-to-use technologies exist for correcting these faults in the field, minimizing the impact of repair on production. This session will make use of case histories as examples for correcting the most common problems.

B2 Vibration Analysis

Monday, June 22, 1:00pm-5:00pm

Maintenance departments today are asked to run with fewer staff and smaller budgets than ever before. In this do-more-with-less environment, maintenance personnel can't afford to continuously chase the next breakdown. They need to quickly and accurately identify developing faults and then get to the root cause of the machinery problem so that it can be fixed once and for all. Vibration analysis using routebased, portable technology has long been the accepted practice for addressing this challenge and moving maintenance from a cost center to a cost-savings center. This session will demonstrate the inspection process, data collection, analysis, and reporting for the most common problems, as well as the technology theory and approach to set up a well-run program.

J2 Infrared and Ultrasonic Analysis

Thursday, June 25. 8:00am-12:00pm

Infrared thermography plays an important part in a predictive maintenance program, as emerging faults are frequently accompanied by excessive heat or heat loss. Typical faults identified through thermographic imaging include machinery wear, anomalies in electrical systems, and insulation damage to process applications as well as buildings and facilities. Ultrasonic Analysis, while applicable on rotating machinery, can expand your predictive maintenance program to cover other nonrotating assets such as valves, steam lines, pressure vessels, vacuum chambers, and even building structures. Leak detection is the primary application for ultrasonic analysis, and plants have reported significant savings by locating and removing leaks in plant air, steam lines and other pressurized systems. This session will demonstrate the inspection process, data collection, analysis and reporting for the most common problems, as well as the technology theory and approach to set up a well-run program.

Tuesday, June 23, 8:00am-12:00pm

C2 Oil Analysis and Lubrication Program Management

Second only to vibration analysis, oil and lubrication analysis are widely accepted approaches for determining the health of machinery. Oil and lubrication analysis can identify machine wear, lube system contamination, and chemistry changes of the oil that are indicative of machinery health degradation. An effective lubrication program not only provides early warning of unseen corrosion and wear, it helps

www.totalproductivemaintenanceconference.com

The TPM Experience: Workshop Descriptions

The Pillars of TPM

1

Predictive Technologies

2

Support Tools

3

Culture

4

SUPPORT TOOLS

When embarking on a TPM rollout there are more than just the TPM Pillars to consider.

You must also consider the support areas within your organization and their role in the improvement activities, as well as other lean techniques that will directly and indirectly support your TPM efforts. The modules in this track touch on these important functions and techniques.

A3 Quick Changeover

Monday, June 22, 8:00am-12:00pm

TPM introduces us to the concept of the six big losses, defined by Nakajima as formidable obstacles to equipment effectiveness. Implementation of the Quick Changeover methodology directly addresses one of these losses--set up and adjustment--and will help you dramatically reduce the downtime associated with adjustments from die changes and other machine changeovers. The changeover methodology can also play a major role in reducing the time to complete major machine repairs, PM's, and many more similar applications. This workshop will demonstrate how you can use the principles of changeover to greatly improve a variety of maintenance activities.

C3 TPM Implementation Measurement and Accountability

Tuesday, June 23, 8:00am-12:00pm

The success of your TPM implementation is often measured by the change in critical internal measurements such as throughput, quality and even safety. These numbers reflect how well TPM is working to improve the overall company, but those who are tasked with implementing TPM need quicker, real-time data to steer the implementation effort. Setting up a proper TPM auditing process can be the catalyst to improving the speed and quality of your implementation process. This session will teach you how to design, conduct, report and use the TPM audit to improve your implementation effort.

B3 Problem Solving Using CEDAC

Monday, June 22, 1:00pm-5:00pm

From symptoms to root causes, this module teaches an effective problem solving system that allows the user to create a logic chain. Learn a reliable method for identifying a problem's root cause and for generating effective solutions. Using a powerful kaizen tool called CEDAC (winner of the Deming Prize), unlock your team's knowledge and creativity while learning how to integrate problem solving with improvement tools to focus on "priority" problems and opportunities.

D3 Office TPM and Administrative Systems

Tuesday, June 23, 1:00pm-5:00pm

Unlike the production department, administrative and support departments such as planning, R & D, customer service, and accounting do not add value directly to the product. Yet they play a vital role in the organization's overall value chain. These departments must be flexible in order to respond to a rapidly changing business environment, outperform the competition, and win customer confidence. To accomplish these goals the support departments must define their mission, support the TPM process in the production area, and ask what they can do to enhance their own effectiveness? In this workshop participants will learn the importance of educating, training and involving your administrative areas in the TPM method as well as looking at actual examples of office TPM improvements and outline the associated cost-time savings involved. And in today's challenging economic climate, reducing cost is more important than ever.

It was the most informative program I've attended in memory.

Don Dinero, Round Pond Consulting

H3 5S/Visual Workplace

Wednesday, June 24, 1:00pm-5:00pm

Learn the principles and techniques needed to apply 5S and establish visual management systems to improve workplace communication and adherence to standards. This module will teach you how to share information about daily production problems, abnormalities, waste, and unsafe conditions through visual display and controls so that everyone understands at a glance what is going on in the workplace.

J3 Stores Management

Thursday, June 25. 8:00am-12:00pm

The great necessary evil of any maintenance initiative is the management of the spare parts department. Proper usage and storage of spare parts is not just an exercise in housekeeping, but a critical component in the success of your preventative and planned maintenance activities and an integral part of your overall maintenance improvement initiative. An effective stores management system will save your organization thousands of dollars by ensuring spare parts are on hand and in good condition thus decreasing the potential for duplicate ordering and increasing equipment uptime. In this module you will learn how to properly manage the storage and distribution of your spare parts.

Productivity Inc. 4 Armstrong Road, 3rd Floor, Shelton, CT 06484 www.productivityinc.com 1-800-966-5423 or (203) 225-0451 Fax: (203) 225-0771

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The TPM Experience: Workshop Descriptions

The Pillars of TPM

1

Predictive Technologies

2

Support Tools

3

Culture

4

8

CULTURE

The importance of building an organizational culture that will support your improvement initiatives is paramount to long term

success. Yet still today, most organizations spend the bulk of their training budgets educating their workforce on the technical elements of process improvement leaving very little for the social `tools' so vital to long term success. Today more than ever teams play a critical role in creating effective organizations--empowering employees, generating needed change, and producing solutions to complex problems. The modules included in the Culture Track have been designed to help you build a culture that will not only support, but lead your overall improvement efforts.

A4 TPM Tactical Planning

Monday, June 22, 8:00am-12:00pm

With any TPM implementation, having a tactical plan is critical to the success of the program. Understanding the elements of implementing TPM is important to putting together a solid tactical implementation plan. In this session, attendees will learn the basic foundations of a TPM tactical plan along with tools and techniques to customize the plan for their particular environment. Attendees will leave with a strawman of a plan to build upon for their individual facility or company.

H4 Facilitator Training

Wednesday, June 24, 1:00pm ­ 5:00pm

Today more than ever, teams play a critical role in effective organizations--empowering employees, generating needed change, and producing solutions to complex problems. And one of the key ingredients for successful teams is the facilitator. Developing a cadre of key people who will help sustain the shift in culture and the alignment around the leader's vision and goals is an essential resource that organizations cannot do without. This workshop provides the material needed to develop the behavioral skills of facilitators in fostering and managing culture change while preparing them to focus teams on a process for achieving continuous improvement.

B4 Coordinating and Leading the TPM Effort

Monday, June 22, 1:00pm-5:00pm

Many experts will say that a key person in the organizational structure for TPM implementation is the TPM Coordinator or Champion. But very little is said about the roles and responsibilities of this individual. This session is directed at that individual who has been tasked with implementing TPM. Your TPM Coordinator will learn techniques to help communicate the TPM plan, overcome resistance to change, and gain and sustain support for the initiative.

C4 Supervisor Training: Ten Key Performance Factors for Supervisors in a Lean Organization

Tuesday, June 23, 8:00am-12:00pm

Supervisors play a critical role in the Lean transformation. They are critical links between management hierarchy and the people who do the "real" work. Supervisors can bridge the gap between the current culture and the desired one. Yet despite these complex expectations, most organizations give supervisors limited attention. In this interactive session, learn ten critical performance factors that are necessary to change your culture and where supervisors need the organization's support in order to be successful.

J4 Team Dynamics and Conflict Resolution

Thursday, June 25. 8:00am-12:00pm

Leading a team of people who are trying to improve their operation is an exciting challenge. The team leader or manager needs to help the group move steadily ahead through the process of identifying, analyzing, and developing solutions to problems. Along the way, there are bound to be points of resistance which could lead to conflict among team members. A leader must have the skill necessary to guide the group past the conflict. To accomplish this, a leader needs to have an understanding of the problem-solving process and the capacity to apply the process. In this workshop participants will look at their approach to managing conflict, discover the eight key elements of an effective conflict utilization process, and take a conflict management survey to help them understand more about themselves and how they behave in conflict situations.

D4 Empowering the Workforce

Tuesday, June 23, 1:00pm-5:00pm

Are your employees empowered? Have you provided your process owners with the technical and soft-skill tools necessary to make solid business decisions? In many organizations the answer to these questions is no, yet empowerment holds the key to long term sustainable improvement. To be successful the role of leadership must change but assigning decision-making authority, accountability and freedom to act cannot be done in an arbitrary manner. This workshop provides leaders with a plan to guide the change process and create a truly empowered workforce. Discover what skills today's leaders need to handle rapid change while performing their leadership responsibilities even more effectively.

Loved the interactive nature of the program.

Mike Hester, Personix

This all makes so much sense! I just wish this wasn't a foreign language to the operators in production at our facility! A lot of the content today should help me bridge the gap!!

Melody Crisp, Nike IHM

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The TPM Experience: General Session & Case Study Descriptions

The General Session and Case Studies bring the TPM methodologies to life--hear real people talk about real

implementations. In these sessions learn how your peers are using these techniques, the obstacles they have encountered and the solutions they found to reach success.

GENERAL SESSION AND CASE STUDIES

General Session How to Create a Continuous Improvement Culture

David Rowland, Director of Milliken Performance System Milliken & Company Wednesday, June 24, 7:30am-8:30am

The Milliken Performance System has been effective for the past 12 years, but Milliken discovered early in the process that Lean and SixSigma did not automatically transform the culture. Building a continuous improvement culture takes time and the involvement of all associates. They recognized that to be successful for the long term, they needed a holistic systematic approach to changing the way people think and work. In this session, learn the system Milliken uses to create and sustain a continuous improvement culture in their organization. David Rowland is the Director of the Milliken Performance System. His 23 years of manufacturing experience includes Process Engineering and multiple plant assignments as a Plant Manager. Milliken has won 56 TPM Excellence Awards between 1999­2005. David is a certified TPM instructor through Japan Institute of Plant Maintenance.

Chris Glover has spent the last eight years as a plant leader of operations at Milliken & Co. implementing and sustaining the Milliken Performance System as the foundational operating system. Prior to being a plant leader, Chris served several leadership roles including production manager, process engineer, quality assurance manager, process improvement manager and Milliken Performance System leader since joining the company in 1985.

E3 Case Study

Business Results with TPM--Winning the JIPM Excellence Award

Pamela Quist, TPM Leader Sun Products Corporation Wednesday, June 24, 8:45am-9:45am

The Sun Products factory in Baltimore, MD attributes its consistent year-onyear business improvement and success to its robust TPM process. Through TPM every significant business benchmark has improved allowing Baltimore to achieve its mission and vision to be the lowest cost producer, to involve all employees, and to achieve world class manufacturing. In this case study Pam will share how they have achieved 18% OEE improvement, reduced breakdowns 71% and decreased the operating budget 23%. Pamela Quist is the TPM Leader for Sun Products Corporation. She has been in manufacturing for 18 years and has led and developed TPM in chemical, mining, and consumer products industries. Sun Products is a leading provider of laundry detergent, fabric softeners and related household and personal care products for the North America market.

E1 Case Study TPM Deployment in a World Class Environment

Jennifer Brown, Operational Excellence Analyst Genentech, Inc Wednesday, June 24, 8:45am-9:45am

This session will analyze the organizational structure Genentech has put in place to effectively communicate, train and deploy Total Productive Maintenance. She will look at elements to consider when developing a deployment plan, how to build your training infrastructure, how to communicate the business value to upper management, and potential roadblocks to consider. She will also discuss the TPM audit, measurement criteria and future pillar deployment. Jennifer Brown is an organizational analyst overseeing the implementation of TPM at Genentech, Inc., the world leader and pioneer of bio-pharmaceutical therapy.

F1 Case Study Operational Ownership

Bruce Bletz, Manufacturing Coordinator Dr. Reddy's Laboratories Louisiana, LLC Wednesday, June 24, 10:00am-11:00am

This case study will look at autonomous maintenance concepts and other Lean initiatives presented from a production floor perspective. Operators at Dr. Reddy's are responsible for and are taking pride in their machines with positive results. Equipment inspection and operator training have increased net operating times and decreased overall operating times 22% at this global pharmaceutical company. This presentation demonstrates how shop floor changes and operator involvement are truly the keys to success. There will be discussion of tools used to drive the culture change as well as some of the issues that were encountered along the way. Bruce Bletz is a manufacturing and production coordinator with over 30 years experience in the chemical and pharmaceutical industries. Dr. Reddy's is a global manufacturer of pharma services, active ingredients and generics. They employ 9,000+ employees with 2,000 in the international workforce. Dr Reddy's has 13 manufacturing facilities (chemicals & finished dosages) with a growing presence in North America.

E2 Case Study Lean and TPM in Harmony

Chris Glover, Plant Manager, Valway Mfg. Plant, Lagrange, GA Milliken & Company Wednesday, June 24, 8:45am-9:45am

All industries have a need for both TPM and Lean activities, however many choose one approach versus the other. Milliken & Co. implemented the Milliken Performance System based on TPM principles in 1995. The system has continued to evolve over time and incorporates a Lean enterprise aspect as well as the principles of TPM. This presentation will show how TPM and Lean can be combined to maximize the benefits of both.

The entire seminar has been a great experience.

John Evans, Palm Harbor Homes

Productivity Inc. 4 Armstrong Road, 3rd Floor, Shelton, CT 06484 www.productivityinc.com 1-800-966-5423 or (203) 225-0451 Fax: (203) 225-0771

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The TPM Experience: Case Study Descriptions

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CASE STUDIES

F2 Case Study Recipe for Success: Driving for Results

Heather Mosqueda, Information Service Supervisor, Dave Zenk, Director of Maintenance Services and Don Rettig, Director of Operations Metroparks of the Toledo Area Wednesday, June 24, 10:00am-11:00am

Metroparks of the Toledo Area struggled for several years to implement a successful 5S program in order to better serve their customers and ensure efficient use of taxpayer dollars. Though excellent training was provided and initial efforts appeared successful, the program floundered as time went by. A renewed effort and more focused approach have lead to dramatic improvements and a higher level of sustainability. This case study will look at how this organization is using cross-functional teams, prioritization of projects, clearly articulated standards and a systematic audit process to drive continuous improvement and employee ownership of the new 6S program. The team from Metroparks has extensive continuous improvement experience in both the private and public sectors. They are highly dedicated to leading change to ensure the most effective use of levy generated tax dollars during a period of shrinking revenues and economic uncertainty. By utilizing cross-functional teams and applying maintenance standards and a systematic audit process they have created a highly successful and comprehensive 6S program that is refocusing the entire organization and creating a solid foundation for future success.

bers of retiring baby boomers and the burgeoning cost related to corporate human resource departments in the attempt to handle these issues. In this session Dave Crockett will discuss how companies are addressing this crisis and a structured process to develop a more diversified maintenance organization of tomorrow. David has worked in the industrial maintenance arena for more than 30 years. Prior to CenTec, he directed recruiting and training for 24 Michelin North America facilities in the U.S. and Canada.

G2 Case Study Embedding 5S Visual in the Culture for TPM

Ken Johnson, TPM Coordinator Kaiser Aluminum Wednesday, June 24, 11:15am-12:15pm

We all know 5S Visual is a shared tool in the arsenal of continuous improvement but how do we embed it in the culture for TPM implementation? In this case study Ken will review the history of TPM at Kaiser Aluminum in Newark, Ohio, see what improvements have been made and review how they have incorporated 5S Visual into the implementation plan. During this case study you will see practical applications from tools like simple forms to executing improvement plans with teams. Ken has been with Kaiser Aluminum since November of 2007. He has served in maintenance and engineering positions for over a decade in roles ranging from "tool boy" and maintenance manager to managing a largescale TPM implementation effort.

F3 Case Study Green TPM: Environment and Safety

Ellis New, Senior Management Consultant Productivity Inc. Wednesday, June 24, 10:00am-11:00am

G3 Case Study Early Equipment Management/ Maintenance Prevention Design

Ensuring equipment reliability and preventing human error are not the only objectives of TPM. Eliminating safety incidents and environmental issues are basic tenets of TPM as well. In this workshop participants will learn how the pillars and elements of TPM can be used to create GREEN savings within their facilities and organizations. Ellis has over twenty years experience helping Fortune 500 and Global 1000 organizations implement their process improvement goals. He started his career with Pirelli Cable, where he spent ten years playing a key role in their process improvement initiatives, both at the plant and corporate level. In this role, Ellis planned and deployed TPM, produced the necessary awareness and training materials, and trained over 1000 employees in the principles and practices of TPM. As a result, Pirelli's TPM implementation became a best practices benchmark.

Eric Whitley, Senior Management Consultant Productivity Inc. Wednesday, June 24, 11:15am-12:15pm

A vital part of any ongoing success in the implementation of TPM is the study and application of continuous improvement in the design and engineering of the production equipment. Early Equipment Management is the pillar that applies to the principle of continually improving the equipment at the design phase, before it hits the shop-floor. This case study will introduce the pillar of Early Equipment Management and show you how to better understand how it fits within your implementation efforts. Eric has over twenty years experience working with companies in the manufacturing sector helping them to achieve their continuous improvement goals. Eric was the TPM Coordinator of Autoliv ASP, where he played a key role in the company's TPM and Lean initiatives. His role there started Autoliv ASP down the path to winning the Shingo Prize in 2003, 2005 and 2006 for their implementation efforts.

G1 Case Study Recruit, Train and Assess Your Maintenance Organization of Tomorrow

David A. Crockett, President and CEO CenTec, Inc. (Center for Technology) Wednesday, June 24, 11:15am-12:15pm

Three factors have now combined to create a brewing crisis for all manufacturers: the growing shortfall of skilled workers, the accelerating num-

www.totalproductivemaintenanceconference.com

Why attend a Productivity conference?

Productivity is a Lean Pioneer...

Productivity was the first organization to introduce Total Productive Maintenance and Lean concepts to American manufacturers, the first to offer TPM and Lean training and consulting, and the first to publish books on the subjects.

We have been doing this for a while and we know our stuff...

We have been producing Lean conferences for more than two decades and in the process have launched 1,000 careers! Today there are many Lean conferences on the market...some bigger and some smaller, but none more dedicated to delivering a powerful educational experience, in an interactive and fun environment. Productivity conferences are an educational event unlike any other.

Real Sensei...

Our consultants are "real sensei" taught by the originators of Lean including Mr. Iwata, Mr. Nakao, Dr. Shingo, Dr. Fukuda and others. We understand the origins of Lean and what it takes to make it work in today's complex organizational environments.

To Learn More...

To learn more about Productivity's products and services and our ability to customize our offerings for your individual needs, give us a call or visit our website at www.productivityinc.com.

Cancellation Policy:

Conference registrations may be transferred to another colleague without charge. To be considered for a refund, we must receive notice of cancellation in writing no later than 21 business days prior to the event. Cancellations received within 21 business days are subject to the full fee and money will be held on account for up to one year for use at a future event. If no notification of cancellation is provided, registration fees will be forfeited. There is a $200 processing fee for all cancellations. Consultants and university faculty may be excluded from attendance to some sessions.

GAYLORD OPRYLAND

Hotel Accommodations:

The Gaylord Opryland Hotel: The Conference will be held at the Opryland Resort located at 2800 Opryland Drive, Nashville, TN 37214. A block of rooms is being held for attendees of the conference for the reduced rate of $195.00 single/double occupancy. This special rate will be available until May 22, 2009. After this date the rate is subject to availability. Please call the hotel at (615) 883-2211 and tell them you are attending the Productivity Inc. Total Productive Maintenance Conference or mention code X-PTPMF to receive this special reduced rate. Gaylord Opryland Resort and Convention Center is just minutes from the sights and excitement of Music City. Located on the banks of the Cumberland River, Gaylord Opryland is a short drive from both the Nashville International Airport and downtown Nashville. The Gaylord Opryland Resort is more than just a hotel, it's an indoor city! This 56-acre complex of guestrooms, restaurants, and shopping is anchored by three large glass atriums, with rolling streams and waterfalls, pedestrian bridges, diverse plant life, and a variety of eating and drinking destinations. Amenity highlights: Two outdoor pools, an arcade, and a 27,000-square-foot spa and fitness center--not to mention a sports bar, an Irish pub, sushi bar, and 14 other restaurants and lounges--provide just some of the options for relaxation. For additional details visit their website at www.gaylordopryland.com

Productivity Inc. 4 Armstrong Road, 3rd Floor, Shelton, CT 06484 www.productivityinc.com 1-800-966-5423 or (203) 225-0451 Fax: (203) 225-0771

11

CONFERENCE REGISTRATION

SPECIAL EARLY BIRD DISCOUNT!

Register and pay before April 17, 2009 and recieve 10% off any single registration. Contact us for information on special group discounts. Call us now to hold your spot.

REGISTRATION INFORMATION

Please type, print clearly, or attach business card. Photocopy blank form for additional registrants.

NAME TITLE COMPANY ADDRESS

CONFERENCE SELECTIONS

Please choose one workshop/case study from each time slot.

MONDAY, JUNE 22

8:00am-12:00pm Workshops

A1 Intro to Total Productive Maintenance A2 Predictive Technologies: Overview A3 Quick Changeover A4 TPM Tactical Planning

1:00pm-5:00pm Workshops

B1 Autonomous Maintenance B2 Vibration Analysis B3 Problem Solving Using CEDAC B4 Coordinating and Leading the TPM Effort

TUESDAY, JUNE 23

CITY, STATE, ZIP PHONE ( EMAIL ) FAX ( )

8:00am-12:00pm Workshops

C1 Planned Maintenance C2 Oil Analysis and Lub. Program Mgmt. C3 TPM Imp. Measurement & Accountability C4 Supervisor Training

(Your confirmation will be sent electronically--email is required)

1:00pm-5:00pm Workshops

D1 Pillar of Training and Skills Development D2 Wireless & Continuous Vibration Monitoring D3 Office TPM & Administrative Systems D4 Empowering the Workforce

REGISTRATION FEES

4 DAY PRICE* 3 DAY PRICE 2 DAY PRICE 1 DAY PRICE $2,025 $1,825 $1,425 $795

WEDNESDAY, JUNE 24

7:30am-8:30am General Session 8:45am-9:45am Case Studies

Milliken & Company

Bring your team to the conference and some attend for FREE! Recognizing that budgets are tight, we are offering special group pricing--for every four attendees you send, you will get the fifth attendee FREE! (Groups of 3 individuals will receive a 10% discount off each registration fee).

TOTAL DUE (PAYMENT MUST BE RECEIVED PRIOR TO EVENT) $

E1 Genentech, Inc. E2 Milliken & Company E3 Sun Products Corporation F1 Dr. Reddy's Laboratories Louisiana, LLC F2 Metro Parks of the Toledo Area F3 Productivity Inc. G1 CenTec, Inc. G2 Kaiser Aluminum G3 Productivity Inc. H1 Focused Improvement H2 Laser Alignment and Field Balancing H3 5S / Visual Workplace H4 Facilitator Training

10:00am-11:00am Case Studies

* TPM Practitioner Certificate: Participants who enroll in the educational events Monday through Thursday will earn the TPM Practitioner Certificate.

11:15am-12:15pm Case Studies

METHOD OF PAYMENT

Payment by check or credit card must be received prior to conference. Enclosed is a check for $ Charge my Card # Security Code: V/MC 3 digits from card back, AMEX 4 digits from card front Exp. Date Name on card (please print) Credit Card billing address: MC Visa Payable to: Productivity Inc., drawn on a U.S. bank. American Express

1:00pm-5:00pm Workshops

THURSDAY, JUNE 25

8:00am-12:00pm Workshops

J1 J2 J3 J4

Quality Maintenance Infrared and Ultrasonic Analysis Stores Management Team Dynamics and Conflict Resolution

REGISTRATION OPTIONS:

CALL:

1-800-966-5423 or 203-225-0451

DOWNLOAD

ONLINE:

www.productivityinc.com www.totalproductivemaintenanceconference.com

the registration form on the conference website and fax it back to 1-203-225-0771 or mail it to: Productivity Inc. 4 Armstrong Road, 3rd floor Shelton, CT 06484

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