Total Productive Maintenance and ISO 17024 Kit (Publication Date: 2024/03)

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Discover Insights, Make Informed Decisions, and Stay Ahead of the Curve:



  • What type of procedures should be developed for the calibration and maintenance of equipment?


  • Key Features:


    • Comprehensive set of 1505 prioritized Total Productive Maintenance requirements.
    • Extensive coverage of 96 Total Productive Maintenance topic scopes.
    • In-depth analysis of 96 Total Productive Maintenance step-by-step solutions, benefits, BHAGs.
    • Detailed examination of 96 Total Productive Maintenance case studies and use cases.

    • Digital download upon purchase.
    • Enjoy lifetime document updates included with your purchase.
    • Benefit from a fully editable and customizable Excel format.
    • Trusted and utilized by over 10,000 organizations.

    • Covering: Performance Assessment, Item Response Theory, Security Architecture, Security And Integrity, Testing Environment, Digital Badges, Testing Accommodations, Assessment Criteria, Ethics Standards, Total Productive Maintenance, Certificate Directory, Privacy Policy, Remote Proctoring, ISO 17024, Certification Registry, Facilitated Testing, Competency Standards, Accreditation Process, Information Management, Mutual Recognition, Control System Engineering, Third Party Agreements, Disaster Recovery Strategies, Case Studies, Item Banking, Passing Criteria, Assessment Results, Rating Scales, Certificate Validity, Test Security, Job Analysis, Legal Compliance, Data Protection, Code Of Conduct, Score Interpretation, Internal Audits, Adaptive Testing, CCISO, Diagnostic Assessment, Conflicts Of Interest, Supplier Quality, Multiple Response Questions, Practical Demonstrations, Potential Hires, Formative Assessment, Certificate Verification, Conflict Of Interest, GDPR, Score Reporting, Grievance Process, Issuance Process, Quality Management System, Assessment Methods, Recertification Process, Standards Compliance, Simulation Tests, Psychometric Properties, Test Administration, Candidate Responsibilities, Applicant Rights, Quality Assurance, Personnel Certification, International Recognition, Information Technology, Cut Scores, Record Keeping, Competency Based Job Description, Portfolio Assessment, Occupational Competencies, Computer Based Testing, Eligibility Requirements, Systematic Evaluation, Continuing Education, Test Development, Privacy Protection, Alternate Forms, Item Writing, Observation Checklist, External Audits, Standard Setting, Appeal Process, Complaints And Disputes, Compliance Framework, Validity Studies, Public Information, Action Plan, Continuous Improvement, Marketing And Advertising, Item Analysis, Server Logs, Item Review, Risk Management, Virtual Terminal, Summative Assessment, Work Sample Tests, Service Measurement




    Total Productive Maintenance Assessment Dataset - Utilization, Solutions, Advantages, BHAG (Big Hairy Audacious Goal):


    Total Productive Maintenance


    Total Productive Maintenance is a method for ensuring the efficient operation and maintenance of equipment by developing procedures for calibration and maintenance.

    1. Develop clear and detailed maintenance and calibration procedures to ensure consistency and accuracy.
    2. Implement regular maintenance schedules to prevent equipment breakdowns, saving time and money.
    3. Create a system for identifying and addressing potential equipment issues before they become problems.
    4. Establish a documentation process for recording maintenance and calibration activities, which can be used for audits or reassessments.
    5. Train and certify staff members on proper maintenance and calibration procedures to ensure consistency and quality.
    6. Utilize calibration and maintenance tracking software to streamline the process and ensure all equipment is properly maintained.
    7. Conduct regular equipment reviews to identify any potential upgrades or replacements needed.
    8. Implement an evaluation system to assess the effectiveness of maintenance and calibration procedures.
    9. Establish a contingency plan in case of unexpected equipment failure.
    10. Continuously monitor and improve maintenance and calibration processes to ensure efficiency and effectiveness.

    CONTROL QUESTION: What type of procedures should be developed for the calibration and maintenance of equipment?


    Big Hairy Audacious Goal (BHAG) for 10 years from now:

    In 10 years, our goal for Total Productive Maintenance (TPM) is to achieve a 90% overall equipment effectiveness (OEE) score, improving from our current score of 75%. This will be accomplished by implementing the following procedures for the calibration and maintenance of equipment:

    1. Regular Calibration Schedule: We will establish a regular schedule for calibration of all equipment based on manufacturer recommendations, industry standards, and internal testing results. This will ensure that equipment is calibrated accurately and consistently.

    2. Standardized Calibration Procedures: Standard operating procedures (SOPs) will be developed for each type of equipment. These procedures will include detailed steps for calibration, as well as frequency of calibration, necessary tools and materials, and troubleshooting guidelines.

    3. Documented Maintenance History: A comprehensive maintenance record will be kept for each piece of equipment, documenting the date and type of maintenance performed, as well as any issues or problems encountered. This will provide a clear history of maintenance activities and help identify potential areas for improvement.

    4. Predictive Maintenance Techniques: In addition to scheduled maintenance, we will also implement predictive maintenance techniques such as vibration analysis, thermography, and ultrasonic testing to identify potential equipment failures before they occur. This will help prevent production downtime and improve overall equipment performance.

    5. Employee Training: All employees involved in equipment maintenance and calibration will receive thorough and ongoing training to ensure they have the necessary skills and knowledge to perform their tasks effectively. This will also increase accountability and ownership over equipment maintenance.

    6. Continuous Improvement: We will establish a continuous improvement process for equipment maintenance, where feedback and suggestions from employees will be taken into consideration and incorporated into our procedures. This will create a culture of continuous improvement and drive us towards our OEE goal.

    By implementing these procedures, we believe we will be able to achieve our 90% OEE goal within the next 10 years. This will not only result in improved equipment performance and reduced maintenance costs, but also overall business growth and increased customer satisfaction.

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    Total Productive Maintenance Case Study/Use Case example - How to use:


    Client Situation:

    ABC Manufacturing is a large-scale automotive production company that manufactures various types of vehicles. The company has been facing challenges in terms of equipment breakdowns, frequent maintenance, and low productivity. As a result, the company has been incurring high costs due to downtime and delays in production.

    Consulting Methodology:

    To address the client′s issues, our consulting firm recommends implementing Total Productive Maintenance (TPM) as a holistic approach to equipment maintenance. Our team utilizes a systematic and structured approach for TPM implementation, which includes the following steps:
    1. Assessment of current maintenance practices: The first step is to conduct a full assessment of the company′s current maintenance practices, including equipment calibration, preventive maintenance schedules, and maintenance staff skills.
    2. Development of a TPM framework: Based on the assessment, a customized TPM framework is developed, which outlines the procedures for equipment calibration and maintenance.
    3. Implementation plan: A comprehensive implementation plan is developed, keeping in mind the specific needs and challenges of ABC Manufacturing.
    4. Training and education: Employee training and education are crucial for the successful implementation of TPM. Our team conducts workshops and training sessions to educate employees on the importance of TPM, the new procedures for equipment calibration and maintenance, and their roles and responsibilities in the process.
    5. Monitoring and continuous improvement: TPM is not a one-time activity; it requires continuous monitoring and improvement. Our team sets up a monitoring system to track the progress of TPM implementation and identify areas for improvement.

    Deliverables:

    1. Assessment report: A detailed report highlighting the findings from the current maintenance practices assessment and recommendations for improvement.
    2. Customized TPM framework: A tailored TPM framework with documented procedures for equipment calibration and maintenance.
    3. Implementation plan: A comprehensive plan outlining the steps for TPM implementation and timeline.
    4. Training materials: Training materials and workshops for educating employees on the importance of TPM and the new procedures for equipment calibration and maintenance.
    5. Monitoring system: A monitoring system to track the progress of TPM implementation and identify areas for improvement.

    Implementation Challenges:

    1. Resistance to change: Implementing new procedures for equipment calibration and maintenance can be challenging as employees may resist change. Our team addresses this challenge by involving employees in the process and providing them with the necessary training and support.
    2. Limited resources: The implementation of TPM may require additional resources such as software, tools, and training. Our team works with the company to identify cost-effective solutions and obtain necessary resources.
    3. Time constraints: Implementing TPM requires time and commitment from the company′s management and employees. Our team sets realistic timelines and works closely with the company to ensure timely implementation.

    KPIs:

    1. Overall Equipment Effectiveness (OEE): OEE is a measure of equipment performance, availability, and quality. By implementing TPM, the OEE is expected to increase, indicating improved equipment effectiveness.
    2. Mean Time Between Failures (MTBF): TPM aims to reduce equipment breakdowns, thus increasing the MTBF.
    3. Maintenance costs: The implementation of TPM should result in lower maintenance costs due to reduced equipment breakdowns and improved maintenance procedures.

    Management Considerations:

    1. Commitment and support from top management: The successful implementation of TPM requires commitment and support from top management to drive the change.
    2. Employee involvement and empowerment: TPM is a collaborative process that involves employees at all levels. It is crucial to involve and empower employees to take ownership of the equipment they operate and maintain.
    3. Continuous improvement: TPM is an ongoing process that requires continuous monitoring and improvement. It is essential for management to continue supporting and promoting TPM even after implementation.

    Citations:

    1. Whitepaper: Total Productive Maintenance: A Holistic Approach to Equipment Maintenance by MRC Consultants (2018)
    2. Journal article: A Study on Total Productive Maintenance and its Impact on Manufacturing Performance by V. R. Bagewadi and A. D. Paladka (International Journal of Advanced Research in Management and Social Science, 2014)
    3. Market research report: Global Total Productive Maintenance Market – Growth, Trends, and Forecast (2021-2026) by Mordor Intelligence (2021)

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