FMM Institute (475427-W)

Penang Branch

TOTAL PRODUCTIVE MAINTENANCE

(TPM) FOR MAINTENANCE
PERSONNEL
19-20 September 2012, Wednesday-Thursday
9.00 am – 5.00 pm
Training Venue:
FMM Institute, Bandar Seberang Jaya, Penang

SBL SCHEME
100% CLAIMABLE FROM PSMB

INTRODUCTION

Total productive maintenance (TPM) is a new way of looking at maintenance, or conversely, a

reversion to old ways but on a mass scale. In TPM the machine operator performs much, and
sometimes all, of the routine maintenance tasks themselves. This auto-maintenance ensures
appropriate and effective efforts are expended since the machine is wholly the domain of one
person or team. TPM is a critical adjunct to lean manufacturing. If machine uptime is not
predictable and if process capability is not sustained, the process must keep extra stocks to buffer
against this uncertainty and flow through the process will be interrupted. One way to think of TPM
is "deterioration prevention" and "maintenance reduction", not fixing machines. For this reason
many people refer to TPM as "total productive manufacturing" or "total process management". TPM
is a proactive approach that essentially aims to prevent any kind of slack before occurrence. Its
motto is "zero error, zero work-related accident, and zero loss".

CONTENTS
DAY 1

Introduction

 Investment in Automation versus Maintenance

 Planning and Scheduling
 Maintenance Backlog
 Maintenance Department Organization

Statistical Applications
  What is Reliability
 Basic System Configuration
 Failure Rate
 Mean Time Between Failure (MTBF)
 Mean Downtime (MDT)
 Life Cycle Failure Rate
 Appropriate Preventive Maintenance (PM) Interval
 Economic Analysis
 Queuing Theory

Preventive Maintenance (PM)

 Routine PM
 Major PM
 Equipment History
 System of Criticality
 Planning for PM
 Design for Maintainability
 Cost of PM

Predictive Maintenance (PdM)

 Data Collection
 Data Analysis
 Vibration Analysis
 Vibration Standards
 Effect of Vibration Level on Equipment Condition
 Vibration Trend and Signature
 Vibration Signature and Engineering Limits
 Vibration Monitoring Equipment
 Chemical Analysis
 Spectrography
 Chemical Analysis Equipment
 Thermography
 Infrared Imaging
 Ultrasound Equipment and Techniques

DAY 2

Non-Destructive Testing and Evaluation

 Eddy Current
 Radiography
 Radioscopy
 Tomography
 Magnetic Resonance Imaging

Implementation of TPM and Process Improvement Tools

 Bench Marking
 Failure Mode Effect and Analysis (FMEA)
 Risk Priority Number (RPN)
 Root Cause Analysis (RCA)
 Common Sense Approach
 Change Management
 Events and causal Factors Analysis
 Ishikawa Diagram
 Fault Tree Analysis

Maintenance:- Project Planning and Control

 Successful Project Management
 Project Manager’s Responsibilities
 Steps in Project Management
 4 Major Phases in a Project
 Managing the Team
  Managing Operations Procedure
 Regular Maintenance Works Identified
 Estimate Time
 Estimate Effort

DAY 3
Plant Visit and a Practical Session. To Observe and Study:-
 The methods to assemble/disassemble an equipment
 The common problems encountered whilst repairing
 The methods involved in the replacement of worn/damaged moving parts etc
 Any other operational/maintenance issues.

Objectives
The objective of this program / course is to introduce participants to good manufacturing practices,
to improve and develop further the participants appreciation in these areas and also on how to
overcome problems etc. associated with manufacturing.
At the end of the program, participants will be able to:-

 develop a working knowledge of the various maintenance procedures and techniques;

 implement strategies and methodologies to create an effective maintenance program ;
 enhance their knowledge and skills to identify and address maintenance problems at all levels;
 implement maintenance procedures that are cost effective and aligned to the organization’s
strategic goals;
 improve performance by developing detailed specifications with service partners;

THE FACILITATOR

Ir. Jayaseelan obtained his Higher National Diploma in Mechanical Engineering from Leeds
Polytechnic (UK) and subsequently a Bachelor Degree (Honours) in the same discipline from the
University of Malaya. He has about 23 years of working experience in various industries, which
include manufacturing, building maintenance, foundry, water and sewerage industries. He has vast
theoretical and practical knowledge of the various M&E equipment used in industry. He also writes
technical articles for various international journals and magazines. He is a recipient of the
Association of Overseas Technical Scholarships (MOTS) award on two occasions, awarded by the
Ministry of Economy, Trade and Industry of Japan.

TARGET GROUP
Facilities engineers, maintenance engineers, design engineers, production and manufacturing
engineers, process engineers, process designers, plant engineers, technicians and any one
involved in manufacturing related work and would like to widen their knowledge.

ADMINISTRATIVE DETAILS

COURSE FEE RM850 (FMM Member) / RM980 (Non-Member) per participant

(The fee includes luncheon, coffee/tea breaks and notes)

DRESS CODE Office Attire

REGISTRATION Participation in the program is based on a first-come-first-served

basis. Cheques made in favor of the “FMM Institute” should be forwarded
on or before program date to the FMM Institute, Northern Branch, Bandar
Seberang Jaya. Participants who registered but did not attend, will
be billed accordingly. Upon confirmation, kindly send us the
payment before the commencement of the program.

CANCELLATION There will be no refund for cancellation within 2 days prior to the program,
50% for cancellation between 3 – 6 days and full refund for cancellation 7
 days prior to the program. Please inform in writing if you intend to cancel.
A replacement can be accepted at no additional cost.

DISCLAIMER The FMM Institute reserves the right to change the facilitator, date and
to vary / cancel the program should unavoidable circumstances
arise. All efforts will be taken to inform participants of the changes.
Upon sending the registration form, you are deemed to have read
and accepted the terms and conditions.

ENQUIRIES Ms Nazliza / Haffiz / Aidi

FMM Institute
No 2767, Mukim 11, Lebuh Tenggiri 2, Bandar Seberang Jaya,
13700 Seberang Perai
Tel : 04-6302052 ( Nazliza ) / 04-3992057 ( Haffiz ) / 04-6306050 (Aidi)
Fax : 04-6302054
Email : fmmpenang@fmm.org.my
nazliza@fmm.org.my
haffiz@fmm.org.my

CLOSING DATE 12 September 2012

REGISTRATION FORM

TOTAL PRODUCTIVE MAINTENANCE (TPM) FOR MAINTENANCE PERSONNEL

19-20 September 2012, Wednesday-Thursday
9.00 am – 5.00 pm
Training Venue:
FMM Institute, Bandar Seberang Jaya, Penang

To : Ms Nazliza / Haffiz / Aidi
( Fax : 04-6302054 )
(Email: nazliza@fmm.org.my / haffiz@fmm.org.my )
FMM Institute (Penang Branch)
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participant(s) made in favour of “FMM Institute”
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2. Name :______________________________________________ Company:_____________________________________

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Email:_________________________________________________
3. Name :______________________________________________
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