Equipment and Facilities are usually the most significant assets appearing on the balance sheet. The fundamental aim of lean is to increase throughput dollars using the existing capital assets. When equipment and facilities are not used effectively, it often results in insufficient capacity and causes overtime, additional equipment purchases, poor customer satisfaction and even facility expansion. Lean Asset Management offerings are geared to making the most effective use of machines and equipment, and facilities to allow the greatest throughput with the least amount of capital investment.
Total Productive Maintenance (TPM)
TPM is a method to proactively maintain machines and equipment at their peak productivity to increase return on capital assets. The 8 Pillars of TPM increases overall equipment effectiveness and helps avoid interruptions to production to achieve reduced batch sizes and increased equipment performance. It is often the first key strategy of the Lean Enterprise Operating System that is deployed since it enables the others.
Over 70% of the causes of machine failures result from just 3 things – contamination, improper lubrication, and loose nuts/bolts or other mechanical fasteners. The 7 step Autonomous Maintenance methodology forms the foundation for TPM by equipping operators to perform basic machine inspection, lubrication, and cleaning functions to dramatically decrease machine failures. This creates greater machine uptime and utilization, and begins to free up skilled maintenance technicians to focus on proactive maintenance activities by reducing ‘firefighting’ and unexpected machine failures. Available as on-site deployment project.
Set-up Reduction/Quick Changeover
This course teaches the fundamental principles of set-up reduction. The instructor will clearly define set-up and discuss reasons and barriers to reducing set-up time. Participants learn the standard methodology in applying Single Minute Exchange of Dies (SMED) to any type of set-up or industry.
Plant & Warehouse Layout/Relocation/Expansion
Poor layout can result in excess handling and inventory, reduced process speed, increased expediting, and poor communication. This workshop details the steps of analyzing, designing, and implementing an improved facility layout to achieve maximum velocity of product moving through the system to produce income while minimizing the resources required. Participants learn a proven methodology to make the most efficient use of the existing facility or designing improvements for an anticipated plant expansion or relocation.
Other supporting TMAC offerings include Maintenance Technician Skills – (Pneumatics, hydraulics, electrical, and mechanical systems.)