june 21-24, 2010 tpm › ... · the lean/tpm relationship is epitomized by the race car/race team...

ExperienceThe

www.totalproductivemaintenanceconference.com

TPMA four-day conference

designed to help you achieve Maintenance Excellence

June 21-24, 2010 Mooresville, North Carolina

Featuring hands-on sessions at NASCAR Race Shops

ExperienceTheTPM

June 21-24, 2010 Mooresville, North Carolina

This conference will feature hands-on activities at local race shops allowing you to utilize the techniques you learn in the classroom out on a working race shop floor.

More than simply a car on a race track; racing is a business just like any other business with issues, barriers and the need to continuously improve. Trying to find profits and business sustainment, race-teams are looking to employ improvement techniques such as TPM to improve their processes. They are on a constant quest to combine the latest technology with meticulous human effort and team work to become better than the compe-tition. There are many parallels between motorsports and manufacturing. So you’re not a fan of racing...that’s ok, because even if you are only a fan of improvement, this event provides an opportunity to see how Total Productive Maintenance and Lean techniques are universally applied to all business settings, including the business of motorsports.

• 35 sessions• 10 hands-on sessions

The event includes:• 15 general & knowledge transfer sessions• 9 case study presentations

• 2 networking events


The Lean/TPM relationship is epitomized by the race car/race team relationship, so what bet-ter location for Productivity to host this year’s event than Mooresville “Race City USA”, North Carolina, approximately 30 minutes north of Charlotte and home to some of the biggest names in NASCAR.

About the Conference

A four-day conference designed to help you achieve Maintenance Excellence

Featuring hands-on sessions at NASCAR Race Shops

2

Not a race fan?

Equipment Breakdowns are:

Yet in many organizations, both major and minor equipment breakdowns are considered a normal part of daily operations.They shouldn’t be…

Ladies and Gentlemen…Start Your EnginesIf you are ready to get your equipment reliability issues in check, then join us for The TPM Experience—a four-day, hands-on event where you will learn and experiment with equipment reliability techniques that will allow you to transition from reactive to a proactive maintenance environment.

Organized into three tracks, Plan, Do and Lead, the event features four-hour in-depth knowledge transfer sessions, hands-on implementation sessions, and one-hour case study presentations.

Choose from over 35 sessions and build a curriculum that best suits your individual needs.

These sessions focus on the preparatory phase of the TPM process—what needs to be done to create a solid foundation for TPM implementation and sustainment.

Chances are you already know you must do something to improve the reliability of your equipment, but you may not know exactly what to do or how to get started. This event will provide you with the answers and direction you need.

These sessions focus on the techniques and methodologies you need to transition your organization from a reactive to proactive maintenance excellence environment.

These sessions focus on the cultural and leadership characteristics necessary to keep your effort on track and ensure all of your improvement efforts are in support of the organization’s overall goals.

Costing you Money And Threatening your Competitiveness…

Wasting your Time

Plan

Lead

Do

BRING A TEAM TO THE CONFERENCE AND SAVE!Bring a team of associates to the conference and take advantage of all of the learning opportunities. Register three people and receive 10% off each registration. Register four people for the event you get the fifth free. Larger groups, please call for special pricing. Register today!

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 3

K1 Team-Based Problem Solving (CEDAC)

K2 Team Dynamics and Conflict Resolution

1:15pm-3:00pmLEADDO

D1 TPM Audit andAccountability

D2 Maintenance

Planning & Scheduling

D4 Over the Wall:The PIT Training Experience

D3 Quality

Maintenance

D5 Empowering the Workforce

and Supervisory Skills

8:00am-12:00pm

PLAN LEAD

8:30am-12:00pmGENERAL SESSIONS

12:00pm-1:00pm

12:00pm-1:00pm

12:00pm-1:00pm

12:30pm-1:15pm

9:10am-10:10am

10:20am-11:20am

11:30am-12:30pm

TPM Context and Strategy Have You Put Yourself in Position to Win?Ellis New, Sr. Management Consultant and Eric Whitley, ConsultantProductivity Inc.

Breon Klopp, Sr. Director of Development, Performance Instruction & Training Center (PIT) and Michael J. Kuta, Managing Partner, Productivity Inc.

Luncheon

Luncheon

Luncheon

Luncheon

F1 Case Study: American Woodmark, Inc.

G1 Case Study: Delta Airlines, Inc.

H1 Case Study: Boeing Canada

F2 Case Study: Sensus F3 Case Study: Productivity Inc.

G3 Case Study: Acme Alliance, LLC

H3 Case Study: L.B. Foster Co.

G2 Case Study: Aurora Casket Company, Inc.

H2 Case Study: Wrigley

A1 TPM Tactical Planning

B1 TPM Action

Planning

C1 5S & Visual Controls

E1 Quick Changeover

B2 AutonomousMaintenance

C2 Mistake-Proofing for

Machines

E2 Stores Management

C4 Standardized Work

B3 Predictive Technologies Overview

and Business Benefits

C3 Predictive Tech Tools Test Drive

E3 Early Equipment Management

A3 Coordinating and Leading the TPM Effort

B4 Training and Skills

Development

C5 Over the Wall: The PIT Training Experience

E4 Over the Wall: The PIT Training Experience

A2 Focused Equipment Improvement

This icon denotes sessions that include hands-on activities at local race shops and the Performance Instruction and Training (PIT) Center.

2010 TPM Conference—Week at a Glance June 21-24, 2010 | Mooresville, NC

1:00pm-5:00pm

8:00am-12:00pm

1:00pm-5:00pm

1:00pm-5:00pm

5:30pm-8:30pm

5:30pm-8:00pm

8:00am-9:00am

Networking Event at Dale Earnhardt, Inc.

Networking Event at “The Pit” Indoor Kart Racing

GENERAL SESSION: Assessing Progress in your TPM Program, CertainTeed

MONDAY, JUNE 21, 2010

TUESDAY, JUNE 22, 2010

WEDNESDAY, JUNE 23, 2010

THURSDAY, JUNE 24, 2010

PLAN

PLAN

LEAD

LEAD

DO

DO

DO

HANDS-ON ACTIVITIES

HANDS-ON ACTIVITIES

www.totalproductivemaintenanceconference.com4

Choose from over 35 sessions including 10 hands-on sessions and customize the conference around your individual needs.

As with any TPM implementation, understanding the elements of TPM and having a tactical plan that directly links to your company’s overall strategic plan is critical to the success of the process. In this session, attendees will learn the basic foundations of TPM tactical planning along with tools and techniques to customize a solid tactical plan for their particular environment. Attendees will leave with a “straw-man plan” they can use to build upon for their individual facility or company.

TPM is not a maintenance program. TPM is, or should be, an integral part of your organization’s business improvement strategy. TPM builds upon estab-lished equipment-management approaches that foster team work, improve quality, enhance safety, and build robust processes by maximizing production system overall effectiveness. This session will explore TPM in the context of overall operations improvement and how it aligns with an organization’s improvement strategy.

While TPM and Lean practices have been successfully implemented in many companies with excellent results, not every company implementing these techniques has found success. Why is that? It boils-down to three interre-lated suggestions: articulation, management, and focus. Drawing parallels from NASCAR, and the race teams that make things happen, this session will provide insights into what it takes to plan, do, and lead in today’s competitive and ever-changing business environments.

Ellis New, Senior Management Consultant and Eric Whitley, Consultant, Productivity Inc.

Breon Klopp, Senior Director of Development, Performance Instruction and Training Center (PIT) and Michael J. Kuta, Managing Partner, Productivity Inc.

Focused Improvement is one of the original pillars of TPM. In contrast with autonomous maintenance, which is intended to prevent accelerated deterio-ration 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.

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.

Formed by Dale and Teresa Earnhardt in February of 1980, Dale Earnhardt, Inc. is home to the 2001, 2003 and 2004 Daytona 500 winning cars of Michael Waltrip and Dale Earnhardt Jr. In his career, Dale Earnhardt Sr. won nearly every major event and title available to NASCAR Cup drivers, includ-ing the Daytona 500. Today, DEI remains a vibrant place for competition and success. Through their racing partnerships at Earnhardt Gannasi Racing (winner of the 2010 Daytona 500), Earnhardt Childress Engines, Earnhardt Technologies Group, their philanthropic ventures, and their own living Earn-hardt personalities, they continue the winning ways of Dale himself every single day. Join us for an unforgettable look inside this amazing organization.


TPM Context and Strategy

Have You Put Yourself in Position to Win?



Dale Earnhardt Incorporated

MONDAY, JUNE 21

Knowledge Transfer Sessions 1:00pm-5:00pm

General Sessions 8:30am-12:00pm

Networking Event 5:30pm-8:30pm

Session Descriptions

Action Planning is a valuable asset that can be used to guide the imple-mentation of your TPM Tactical plan or used as a stand-alone tool to help you get focused and get started with an equipment improvement program. An Action Plan begins with an assessment of current state to determine the organization’s readiness to implement TPM including management commitments, roles, responsibilities, etc. Once you have an understand-ing of “where you are”, and have outlined how you want to move forward, the Action Plan will help you determine where to begin your efforts, how to tie your projects back to your organizational (tactical) goals, and how to establish a measurement system that will ensure you are maximizing ROI. In this fast moving session you will learn the process for creating and executing a plan to bring about the greatest amount of improvement in the shortest amount of time and make it stick!

When properly implemented, Autonomous Maintenance can eliminate the causes of 40-60% of unplanned downtime. In this session, 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.

B1 TPM Action Planning

B2 Autonomous Maintenance

TUESDAY, JUNE 22Knowledge Transfer Sessions 8:00am-12:00pm

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

During the receptions you will be taken on an exclusive behind the scenes tour of this legendary facility, visit the “trophy” room featuring trophies and memorabilia from a lifetime spent winning races (not available to the general public), get up close to incredible racing machines and more.

6:00pm-7:00pm: Exclusive Behind the Scenes Tour7:00pm-8:00pm: Reception

Hosted by Productivity Inc. (includes transportation to and from the facility)

5

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 informa-tion 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.

The improper application of maintenance practices in a factory or facility can cause catastrophic failure and even jeopardize the health and safety of employees. Much like Poka-Yoke identifies the error and defects from a quality standpoint and FMEA helps identify potential issues with machine design, Mistake-Proofing for Machines helps identify potential missteps in the application of maintenance practices and then takes the necessary steps to avoid any issues. This tool within the pillar of Early Equipment Design/Maintenance Prevention Design aids maintenance groups with the continuation of improving maintenance practices from all angles.

C1 5S and Visual Controls

C2 Mistake-Proofing for Machines

TUESDAY, JUNE 22 (cont.)

Hands-On Activities (Sessions C1-C5 will be held on the shop-floor of a local NASCAR race team)

1:00pm-5:00pm

Standard Work is central to achieving and sustaining the Lean Enterprise. By definition Standard Work demands adherence to today’s best practices and must be imbedded in all you do, from standard operations in the workplace to standardized policies and procedures. In manufacturing operations, standard work is a key element in the elimination of waste and excess inventory and in achieving balanced and synchronized production. What it boils down to is that absent standard work, there can be no Lean.

Maintenance departments today are asked to run with fewer staff and smaller budgets than ever before. In this do-more-with-less environment, mainte-nance 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. This follow-up to Predictive Technologies Overview will take a deeper dive into the specific tools available to aid your machinery health providing a detailed discussion and demonstration presentation of these technologies and more: Vibration Analysis, Wireless Vibration Monitoring, Laser Alignment and Field Balancing, Infrared Thermography, and Ultrasonic Analysis

This unique hands-on session will take participants to the Performance Instruction and Training (PIT) facility. PIT is the preferred-provider of Pit Crew Training to many of the NASCAR Race Teams. Here, in this state-of-the-art facility, you will get an inside view of how elite pit crews plan, prepare, and perform. You will do an actual Pit Stop on a NASCAR-style race car using the same equipment used in real races. Then you will go through the process improvement phases of discovery, data collection, analysis, experimentation, and standard work. You will develop a current state process map and with your team, analyze the data, determine improvement opportunities, rank opportuni-ties in order of cost vs. impact, experiment with selected improvements (do additional Pit Stops), and develop new standard work. (Note: Space is limited in this special hands-on event.)


C3 Predictive Technology Tools Test Drive

C5 “Over the Wall”: The PIT Training Experience

Tired of sitting on the sidelines? During this after-hours gathering, you can get into the action. The PIT INDOOR KART RACING is one of North Carolina’s premier arcade entertainment destinations with over 100,000 square-feet of floor space. It features a 70,000 square foot kart track, one of the largest single tracks in the country. Get behind the wheel of one of their Sodi RX7 karts, which are not your typical amusement karts. These karts are capable of speeds over 40mph, unquestionably the best adrenaline rush you can have without the high costs of professional racing.

The Pit—Indoor Kart RacingPutting Race Fans Behind the Wheel!

Networking Event 5:30pm-8:00pm

Guided by a classroom simulation, participants will use a proven methodology to develop a standard procedure, and then apply document control and visual workplace principles and techniques to train others in their new best practice, or standard work.

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

B4 Training and Skills Development

B3 Predictive Maintenance Technologies–Overview and Business BenefitsImplementing 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

• Presenting the newest technologies for PdM automation and integration into existing plant systems.

6:00pm-8:00pm: Kart Racing/Reception$45.00 per person (spouses welcome)

Fee includes: Transportation to and from the facility, refreshments, go-cart race and use of other arcade games in the facility.


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, con-duct, report and use the TPM audit to improve your implementation initiative.

Moving from a reactive 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 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.

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 condi-tions 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 integra-tion 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.

D1 TPM Audit and Accountability

D2 Maintenance Planning and Scheduling

D3 Quality Maintenance

Have you provided your process owners with the technical and soft-skill tools necessary to make solid business decisions? Have you provided your supervisors with tools they need to change your organization’s culture? To be successful in today’s operating environment you must have strong leaders, supervisors and an empowered workforce. In this session we will explore what it takes to truly empower your workforce and what role both the leaders and supervisors play in that transition. Discover what capabilities today’s supervi-

D5 Empowering the Workforce and Supervisory Skills

WEDNESDAY, JUNE 23Knowledge Transfer Sessions 8:00am-12:00pm

This unique hands-on session will take participants to the Performance Instruction and Training (PIT) facility. PIT is the preferred-provider of Pit Crew Training to many of the NASCAR Race Teams. Here, in this state-of-the-art facility, you will get an inside view of how elite pit crews plan, prepare, and perform. You will do an actual Pit Stop on a NASCAR-style race car using the same equipment used in real races. Then you will go through the process im-provement phases of discovery, data collection, analysis, experimentation, and standard work. You will develop a current state process map and with your team, analyze the data, determine improvement opportunities, rank opportuni-ties in order of cost vs. impact, experiment with selected improvements (do additional Pit Stops), and develop new standard work. (Note: Space is limited in this special hands-on event.)

D4 “Over the Wall”: The PIT Training Experience

TPM introduces the concept of the six big losses, defined by Nakajima as for-midable 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 change-over to greatly improve a variety of maintenance activities.

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 session you will learn how to properly manage the storage and distribution of your spare parts.

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 session will introduce the pillar of Early Equipment Management and show you how to better understand how it fits within your implementation efforts.

E1 Quick Changeover (the SMED System)



Hands-On Activities (Sessions E1-E4 will be held on the shop-floor of a local NASCAR race team)

1:00pm-5:00pm

This unique hands-on session will take participants to the Performance Instruction and Training (PIT) facility. PIT is the preferred-provider of Pit Crew Training to many of the NASCAR Race Teams. Here, in this state-of-the-art facility, you will get an inside view of how elite pit crews plan, prepare, and perform. You will do an actual Pit Stop on a NASCAR-style race car using the same equipment used in real races. Then you will go through the process improvement phases of discovery, data collection, analysis, ex-perimentation, and standard work phases. You will develop a current state process map and with your team, analyze the data, determine improvement opportunities, rank opportunities in order of cost vs. impact, experiment with selected improvements (do additional Pit Stops), and develop new standard work. (Note: Space is limited in this special hands-on event.)

E4 “Over the Wall”: The PIT Training Experience

sors need to deal with the rapidly changing workplace that will in-turn allow them to carry-out their day-to-day responsibilities at peak-level performance.


Case Studies 9:10am-10:10am

THURSDAY, JUNE 24General Session 8:00am-9:00am


Renata Hafich, Engineering Project Leader, Kathy Wyett, Lean Manager and John Foster, Project EngineerAmerican Woodmark Inc.

F1 Strategic Equipment Excellence: Company-wide TPM Implementation

Wayne A. Marhelski, Vice President of Global Sourcing, Gas Division, Sensus

Ellis New, Senior Management Consultant, Productivity Inc.

A key part of convincing management to take on any new endeavor is being able to state the benefits to the company. Let’s face it, upper management speaks another language and uses a different set of metrics than what is spo-ken/used in operations. In order to capture their attention, you too must speak and present in their terms. Based on his experiences, Wayne will provide you with ideas you can use to create an effective, convincing business case for TPM that will get management’s attention.

Going Green has become a 2010 mantra. Green is on every CEO’s agenda. TPM, with a cornerstone of waste elimination, directly supports the Go Green agenda by helping organizations become environmentally-friendly through reducing wastes (excessive use of energy, water, raw materials, hazardous sub-stances, etc.) that do not add value to the customer. In this session participants will learn how the eight pillars of TPM can be used to assist in meeting environ-mental compliance and concurrently generate a significant Green savings.

F2 Making the Case for TPM—Getting Management Buy-in

F3 Green TPM: Environment and Safety

This case study presentation will follow American Woodmark’s TPM journey. Discover how their program—TPM System of Strategic Equipment Excel-lence —is allowing them to achieve their vision of “continuous pursuit of equipment excellence through technology-driven systems”. Based on her experiences, Renata will walk you through the elements that need to be considered when planning a company-wide TPM implementation, including training, communication, and the challenges to anticipate. AWC’s Five Pillars and methods of managing the cultural change and sustainment process will also be discussed.

Bush Denney, Green Belt and Sharon Robinson, TPM Specialist, Delta Airlines, Inc.

Neil Clayton, Quality Manager, Aurora Casket Company, Inc.

Mike Anderson, General Manager, Acme Alliance, LLC

This session will delve into the processes that Delta Technical Operations has put into place to implement Total Productive Maintenance. Elements of their program that will be discussed include: addressing management issues, creating employee buy-in, establishing teams, conducting annual inspections, scheduling, measuring, and the impact on customer service. The speakers will also discuss how Lean has impacted the overall performance of their operation.

The Quality Maintenance Pillar of TPM uses the tools of Six-Sigma to identify conditions that affect quality and customer expectations. Combining TPM and the tools of Six-Sigma provide a well-ordered approach for achieving total process control. Based on Clayton’s previous experience leading TPM teams at a major automotive manufacturer, the presentation will address a case study in which two individual TPM teams operating separately struggle to meet customer expectations, and how the teams, once properly focused, pulled together to provide solutions using Six-Sigma based methodology and best practices. This session explores the synergy of teams, the concept of the internal customer, TPM Teams, the use of Six-Sigma tools, and the application of Quality Maintenance.

This session focuses on management’s role for implementing and sustaining a successful TPM program. Mike will review the common short-comings of management’s responsibility once TPM is introduced to the shop floor, as well as management participation. He will also discuss what tools and resources management can use for properly evaluating the need to establish a TPM program. The session will also include TPM success stories, but focus more on TPM failures.

G1 TPM—Tapping the Hidden Capacity of Your Equipment

G2 Leveraging TPM Teams for Six Sigma

G3 Management’s Accountability for TPM Success

Case Studies 10:20am-11:20am

CertainTeed Roofing, a high volume continuous manufacturing operation with 13 plants throughout the US, began its TPM journey with Productivity Inc in 2006 with the goal of enhancing planned and un-planned downtime through employee empowerment and ownership. To achieve this goal, they began their initiative by implementing fundamental Lean techniques includ-ing 5S, visual controls, autonomous maintenance, and SMED at each facility. They also recognized that in order to sustain the improvements they made, they would need to develop their people and make these techniques a way of life. What followed was a series of culture change sessions at each of the plants focused on building team work, ownership, and empowerment to ensure clarity and alignment of company vision and goals.

In this session CertainTeed will share details of their TPM journey and spe-cifically how TPM scans, as a means of self assessing progress, are allow-ing them to continually reach their goals. They’ll describe the process and tools used to conduct these scans, show real-life examples of actual scan results and share details on how they are using the scan results internally to share best practices. They will also touch on communication tools that are starting to help with the early equipment management/maintenance prevention design (EEM/MPD) pillar of TPM and helping them improve their Operational Excellence culture.

Now entering their fourth year of implementation, CertainTeed is ensuring their program (which they call a “work in process”) stays on track over the long term. One tool they are using to help make this a reality is the TPM Scan. The TPM Scan is a system of checks and cross-checks that allow leaders and process-owners to track progress, communicate, and collaborate on implementation projects and help uncover issues that need to be addressed.

Wayne Thompson, Manufacturing Manager, John Hardy, Master Black Belt/OP Ex Leader, Tom Nendick, Maintenance Superintendant, CertainTeed Roofing Products Group

Assessing Progress in your TPM Program

Steve Haller, TPM Leader and Don Bicking, Regional TPM Leader,Wrigley

Brent Evans, Senior Manager, Facilities and Equipment, Boeing Canada Operations Ltd., Winnipeg Division

Mark W. Maxwell, Director of Operations,L.B. Foster Company

H2 The Benefits of External TPM Certification

H1 TPM Implementation Journey

H3 Your Total Productive Maintenance (TPM) Program

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. This powerful kaizen tool called CEDAC (winner of the Deming Prize), will allow your teams to unlock their knowledge and creativity while learning how to integrate problem solving with improvement tools to focus on “priority” problems and opportunities.

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 de-veloping solutions to problems. Along the way, there are bound to be points of resistance which could lead to conflict among team members. In order to guide the group past the conflict, 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.

K1 Team-Based Problem Solving (CEDAC)


Knowledge Transfer Sessions 1:15pm-3:00pm


This session will analyze the positive effects that external TPM certification can have, as seen by Wrigley Manufacturing in Gainesville Georgia. During this session they will introduce the JIPM TPM awards and the process for applying for these awards. In addition to this they will discuss some of the specifics about the assessment criteria, their interpretation of these criteria and their implementation approach to achieving these criteria for Level 1 Excellence. They will cover some of the benefits of the assessment for the company as well as the people on the shop floor. Finally, they will do some internal comparison of plants within the Wrigley supply chain looking at those going for the award and those not.

This session will discuss Boeing Winnipeg’s journey of implementing TPM. The presentation will walk through the steps, including initial management and union buy-in, launch of autonomous maintenance, horizontal expansion, and sustainment. Discussion will also include successes, lessons learned, and the cultural shift at Boeing.

This session will provide an opportunity to discover tools and techniques that establish production efficiencies between company management and their workforce. Mark will focus on the development of training events that produce cross-functional teams from multiple locations. He will demonstrate how to design and execute TPM initiatives that promote employee safety, operational efficiency and profitability throughout an organization.

Case Studies 11:30am-12:30pm

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 process-ing fee for all cancellations.

The TPM Conference sessions will be held at the Charles Mack Citizen’s Center, 215 North Main Street, Mooresville, NC 28117.Sleeping Rooms: A block of rooms is being held for TPM Conference attendees at the Hilton Garden Inn, 159 Gateway Blvd, Mooresville, NC 28117.The hotel rate is $119 a night plus 15.5% state and occupancy tax. Please call (704) 663-6468 and ask for Reservations. Mention you are with theProductivity Inc. TPM Conference to receive the special reduced rate. The cutoff date for this rate is May 30, 2010, so please call and make yourreservations as soon as possible. Transportation from the hotel to the Citizens Center will be provided by Productivity Inc.

Consultants and university faculty may be excluded from attendance to some sessions.

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 TPM and what it takes to make them work in today’s complex organiza-tional environments.

Productivity is a Lean Pioneer…Productivity was the first organization to introduce Total Produc-tive Maintenance and Lean concepts to American manufacturers, the first organization to offer TPM and Lean training and consulting, and the first organization to publish books on the subject.

To Learn More… To learn more about Productivity’s products and services visit our website at www.productivityinc.com

For over twenty years Productivity has been helping companies like yours start and continue down the path of TPM. In 1989, Produc-tivity published the quintessential book on TPM, TPM Develop-ment Program by Seiichi Nakajima whose proven and time tested principles remain the foundation of Productivity’s TPM practice.

We have been doing this for a while and we know our stuff…We have been producing TPM conferences for more than two decades and in the process have launched thousands of careers! Today there are many conferences on the market…some bigger and some smaller, but none more dedicated to delivering a powerful educational experi-ence, in an interactive and fun environment. The Productivity confer-ence is an educational event unlike any other.


Accommodations

Cancellation Policy

What makes this event different?

What you will learn?

Built into this event are 10 hands-on application sessions that will allow you to immediately experiment with the techniques you’ve just learned in the classroom out on a working shop-floor, under the guidance of an experienced instructor. Working in teams with other participants in a NASCAR team race shop, you will apply the principles of 5s, Mistake-Proofing, Standardized Work, and others.

Have you ever attended a conference and received a lot of excellent information but had a difficult time translating that information into action back at your facility? If so, then this event is for you.

• Experience real-time PDCA moving from classroom simulation to shop floor execution

• Work along side other participants sharing in the knowledge transfer opportunities

• Gain a usable understanding of the techniques presented; not just information about them

• Leverage the boutique atmosphere allowing for a greater focus on the value add, not the fluff

• Learn then Do translating demonstration into practical application

• Use ‘similarity mapping’ in translating case study presentations into meaningful, usable learning

The TPM Experience: is an intensive learning event that will teach you…

• equipment reliability tools and techniques you can immediately use• how implementation of TPM can help to reduce cost NOW• 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!)

About Productivity

• the needed build people skills in order to maintain the effort

• how and when to apply predictive technologies as part of an overall reliability program

PHONE FAX

CITY, STATE, ZIP

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ADDRESS

COMPANY

TITLE

NAME

EMAIL

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

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

4 DAY PRICE $2,580$2,064

$1,668

$1,192

$636

$45

$2,322

$1,876

$1,341

$715

$45

3 DAY PRICE $2,085

2 DAY PRICE

1 DAY PRICE

TUES. EVENING NETWORKING EVENT

$1,490

$795

$45

REGISTRATION FEES April 2 (Early-bird) May 1 (Early-bird) After May 1

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) $

Payment by check or credit card must be received prior to conference.

METHOD OF PAYMENT

Charge my MC Visa American Express

Enclosed is a check for $ Payable to: Productivity Inc., drawn on a U.S. bank.

Card #

Security Code: V/MC 3 digits from card back, AMEX 4 digits from card frontExp. Date

Credit Card billing address:

Name on card (please print)

CONFERENCE SELECTIONSPlease choose one workshop/case study from each time slot.

MONDAY, JUNE 21

TUESDAY, JUNE 22

WEDNESDAY, JUNE 23

THURSDAY, JUNE 24

1:00pm-5:00pm

8:00am-12:00pm

8:00am-12:00pm

9:10am-10:10am

8:00am-9:00am

10:20am-11:20am

11:30am-12:30pm

Knowledge Transfer Sessions



Case Studies

General Session

Case Studies

Case Studies

Hands-On Activities

Hands-On Activities

1:00pm-5:00pm

1:00pm-5:00pm


B1 TPM Action Planning

D1 TPM Audit and Accountability

F1 American Woodmark

CertainTeed

G1 Delta Airlines

H1 Boeing Canada

F2 Sensus

G3 Acme Alliance, LLC

H3 L.B. Foster Company

C1 5S and Visual Controls

E1 Quick Changeover


B3 Predictive Technologies Overview and Business Benefits

D3 Quality Maintenance

B4 Training and Skills Development

D5 Empowering the Workforce and Supervisory Skills

C3 Predictive Tech Tools Test Drive


C5 Over the Wall: The PIT Training Experience


B2 Autonomous Maintenance

D2 Maintenance Planning and Scheduling

G2 Aurora Casket

H2 Wrigley

F3 Productivity Inc.

C2 Mistake-Proofing for Machines



E4 Over the Wall: The PIT Training Experience

D4 Over the Wall: The PIT Training Experience

1:15pm-3:00pmKnowledge Transfer Sessions

K1 Team-Based Problem-Solving (CEDAC)


Conference Registration

Register three people and receive 10% off each registration. Register four people for the event you get the fifth

free. Larger groups, please call for special pricing.

Register today!

GROUP DISCOUNTS!

Registration Options:

CALL:

DOWNLOAD:

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

For a downloadable registration form go to www.totalproductivemaintenanceconference.com and fax it back to 1-203-225-0771 or mail it to:Productivity Inc. 4 Armstrong Road, 3rd floor Shelton, CT 06484


june 21-24, 2010 tpm › ... · the lean/tpm relationship is epitomized by the race car/race team...

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