the people side of world-class manufacturing and maintenance

More On Our Workshops

Lean Equipment Management: How to Make the Pillars of TPM Work
One-, two-, and three-day options

NASCAR Racing: A Model for Equipment Reliability and Teamwork
One or two days

Focus on Results Maintenance and Operations Skills Development
One to two days

Spanish Seminars
Available upon request

Lean Equipment Management Pit Stop Training
Three to four days

Pit Stop Training Progress Follow-up
One or two days

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Lean Equipment Management Pit Stop Training

Three to four days

Our four-day "Pit Stop Training" is based on proven methods for achieving fast, focused, and sustainable equipment results. The Pit Stop also begins a subtle "team building" experience among the participants. And lastly, using proven methods sets the stage for a "work culture change" in the plant, one machine at a time. The bottom line here is to "Focus on results and change the culture along the way."

The success of Pit Stop training sessions depends on several "critical success factors:"

1.    Focus on results: A compelling business case for improving equipment performance and reliability (effectiveness): Production constraint, high downtime, high cost, late customer shipments, high turnover, etc. Quantify losses from "Total Downtime" and interruptions to production.

2.    Led from the top: Focused improvement led by the Plant Leadership Team and Production/operations (not by "Maintenance")

3.    Follow the data: Equipment-specific data that communicates the opportunities for improvement in support of the "business case"

4.    Teamwork works: The right people involved in the Pit Stop training session to learn and begin applying the "Team-Based" approaches to improving equipment effectiveness. True cross-functional participation by those directly responsible for, by those who touch the targeted equipment, and by those with decision making authority over the targeted equipment.

5.    Applied learning methods: Quality time on the targeted equipment to learn how to apply the techniques learned in the Pit Stop classroom training portion of the sessions. Engaging all six basic "Pillars" of TPM to address the equipment losses identified. Adults learn best by "doing."

The basic "Pillars of Total Productive Maintenance" (TPM) form central strategy used in out Pit Stop Training. We teach the original intent of TPM as "interdependent Pillars" or principles for eliminating equipment losses.

Basic Pillars of TPM:

1. Improving equipment effectiveness by targeting the major causes of poor performance

2. Involving operators in the routine maintenance of their equipment

3. Improving maintenance efficiency and effectiveness

4. Improving skills and knowledge

5. Designing for operability and maintainability

+ 6. Winning with teamwork focused on common goals (implied in TPM)


Recommended Pit Stop Participants

Lean Equipment Management and TPM rely on developing a sense of "ownership" among those who directly, and indirectly, affect equipment effectiveness.  To accomplish this we recommend that all operators of the selected Pit Stop targeted machines be involved in the training session. This may mean that operators from other shifts be scheduled to work on days during the training sessions.

The maintenance mechanics and electricians that are usually assigned to work on the equipment in the pilot areas should also be scheduled to participate in the entire training session.  Maintenance Planner/Schedulers and spare parts warehouse personnel are critical to changing maintenance practices.

Process performance and reliability is critical. To that end process engineers/technicians and quality control representatives from the area should actively participate in the Pit Stop.

Supervision and management who have direct responsibility for the machines in the pilot area should also plan on participating in the training session.  This will not only familiarize them with the new approaches for improving equipment effectiveness but also send the message that "TPM is important for our business."

Training Department/Human Resources representatives may be helpful if they have direct operations and/or maintenance training responsibilities.

Equipment manufacturers/representatives can offer invaluable insights as Pit Stop participants and should be invited to participate whenever feasible.

Steering Committee (or TPM Core Team) Representatives responsible for leading change and reinforcing follow-through with the skills learned. By involving members of the TPM Steering Team, Strategic Work Systems will transfer much of the TPM PIT Stop training techniques for use throughout the Plant in the future using internal facilitators. Our role will then become more of a coach than an active facilitator in the TPM development activities at the plant.