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Pillar IV : Training and Skills

Development
Objectives
1) Enhance employees’ ability and skill in TPM methods
2) Provide necessary TPM methodology at the right time

TPM

ADMINISTRTIVE WORK IMPROVEMENT


Consolidation

TRAINING AND SKILLS DEVELOPMENT


FOCUSED IMPROVEMENT

PREVENTION OF MAINTENANCE

SAFETY AND ENVIRONNEMENT


AUTONOMOUS MAINTENANCE
Expansion
PLANNED MAINTENANCE

QUALITY IMPROVEMENT
OEE INCREASE/

(Initial Phase Control)


Implementation
Introduction
POLICIES, OBJECTIVES, PERFORMANCE INDICATORS

3) Provide challenge targets for individuals by clarifying


the hierarchy of skills

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Steps for Pillar 4 “Training”
• Step 1: Skills/Techniques Inventory and Hierarchy
 Create a list of Operational and Maintenance Skills and
Techniques
• Step 2: Design Training System
 Including follow-up system such as OJT (=on the job
training)
 Documentation of Individual Skill Levels
• Step 3: Set Individual Skill Challenge Target
• Step 4: Training and Evaluation

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Pillar 4 - TRAINING
• It is aimed to have multi skilled employees whose morale is
high and who has eager to come to work and perform all
required functions effectively and independently.

• They are trained to achieve 4 phases of skills


Phase 1 : Do not know
Phase 2 : Know the theory but cannot do
Phase 3 : Can do but cannot teach
Phase 4 : Can do and also teach

• Policy
- Focus on improvement of knowledge and skills
- Create a training environment for self learning
- Training to remove employee fatigue and make work
enjoyable
Pillar - Training and Skill Development
A structured program for developing associate skill and knowledge to support
TPM implementation and improvement

NAME MACHINE GRIND ASSEMBLE TEST PACK


 Skill levels should be defined
and tracked
BOB
 Maintenance leads most of
the training MARY

 Training goals should be


SUE
established and measured
DAVE

= Fully Competent = Partially Competent = Not Trained


Why Machine Fails
- 5 Levels of Skills

Level 1: Don’t know (not educated) - Lack of


knowledge
Level 2: Know only in a theoretical sense -
Shortage of training
Level 3: Can partially do it - Shortage of training
Level 4: Can do it with self-confidence - State of
having bodily learned it
Level 5: Can teach others - State of completely
mastered it
Pillar 4 – TRAINING Contd..
• Target
- Achieve and sustain downtime due to want men at zero
on critical machines.
- Achieve and sustain zero losses due to lack of
knowledge/skills/techniques.
- Aim at 100% participation in suggestion scheme.

• Steps in education and training activities


- Setting policies and priorities and checking present
status of education and training
- Establish a training system for skill upgrading
- Preparation of training calendar
- Evaluation of activities and study of future approach
Pillars of TPM
• PILLAR - Education & Training
– Skills development for uniformity of work practices on machines.
– Skills for Zero defects, Zero breakdowns & Zero accidents.
– Multi Skilled employees in all departments
• Steps in Educating and training activities :
– Setting policies and priorities and checking present status of education and
training.
– Establish of training system for operation and maintenance skill up
gradation.
– Training the employees for upgrading the operation and maintenance skills.
– Preparation of training calendar.
– Kick-off of the system for training.
– Evaluation of activities and study of future approach.
– A clear understanding of the criteria for judging normal and abnormal
conditions
– The ability to quickly respond to any and all abnormalities
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SIMS
Pillars of TPM
• Four Levels of Skills
– Level 1: Lack both theoretical and practical ability (needs to be
taught)
– Level 2: Knows theory but not in practice
– Level 3: Has mastered practice but not theory
– Level 4: Mastered both practice and theory

SRI SAIRAM INSTITUTE OF TECHNOLOGY &


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SIMS
Pillar IV : Training & Skills

Training and Skills Development:


Program and Matrix
Dry Manufacturing

BOBADILLA, Andres

CAMPOS, Jose V.
2nd Shift
ARAGON, Donald
Training Schedule by Production Line

1st Shift

BARRIOS, Daniel
Training Matrix

ALFARO, Paulo

COBIAN, Marco
BARKER, Brett
ARMAS, Juan
for Manufacturing
and Distribution Staff
Line #1
Training
Week Subjects (L2 refresher)
Hours
x Bidding For / Current Station
I In Training
Plan Actual
Q Trained / Qualified TPMBasics / Concepts
C Ceritifed / Performance Std. Met
5 S's
Dry Manufacturing Understanding OEE - Identifying Losses
1 Helper/Packer Relief
Bag Printer Pillar 2: Autonomous Maintenance
Glue Machine
Labeler
- Overview of 7 Steps
Forklift AMStep 1 - Initial Cleaning Gantt
2 Packer 1 & 2 Initial Inspection / Initial Clean / F-Tagging
Packer/Dribbler
Bag Form er
Actual Initial Cleaning Day
Sew ing Machine Top Management Audit-1
Coder
Bottom Conveyor Belt AMStep 2 - Source of Contamination
Stitcher / Sew ing Machine
Incline Belt
F-Tag Analysis
Cover Pan Prioritize them
Metal Detector
Palletizer
Generate Countermeasures-1
Prioritize Cleaning Area
3 Packer 3 & 4
Packer Generate Countermeasures-2
Metal Detector
Coding
Action Planning
Bulk Bag Filler AMStep 3 - Document / Create Standards
Rovem a
Scale One Point Lessons = Create / Document
Metal Detector Visual Controls = Create / Document
Coding
Define Cleaning Methods =AMCreate / Document
Top Management Audit-2

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Pillar IV : Training & Skills

Training and Skills Development:


Program and Matrix
P i l l a r 2 - A u to n o m o u s M a i n te n a n c e

1 = L e c t u re 1 = E x p o s u re

2 = K n o w le d g e 1 2 2 = C a n E x p la in

3 = A p p lic a t io n 4 3 3 = Can Do / Has done

4 = P a s s o n K n o w le d g e 4 = C a n T e a c h _ H a s t a u g h t - a s e vid e n c e d b y g re e n in d ire c t re p ro t s

O ve rvie w A M A M -S t e p 1 A M -S t e p 2 . . . . S tep 2 A M -S t e p 3

S t e p s 1 -7 C l e a n to I n sp e c t S o u rc e s C o n t a m in a t io n S im p lific a t io n W o rk S t a n d a rd s / A M s

I n sp e c t to D e te c t L u b ric a t io n D e te c t to C o r r e c t

1 2 1 2 1 2 1 2 1 2

4 3 4 3 4 3 4 3 4 3

1 2 1 2 1 2 1 2 1 2

4 3 4 3 4 3 4 3 4 3

1 2 1 2 1 2 1 2 1 2

4 3 4 3 4 3 4 3 4 3

1 2 1 2 1 2 1 2 1 2

4 3 4 3 4 3 4 3 4 3

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B LO O M ’ S TA XO N O M Y O F
E D U C AT I O N A L O B J E C T I V E S

1. Cognitive Domain (Mental abilities)

2. Affective Domain (Feeling and Attitudes)

3. Psychomotor Domain (Performing or Doing)

The three domains are in a


hierarchical order
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MAIN CATEGORIES OF HUMAN BEHAVIOUR

Mental
Cognitive
abilities
Domain
(HEAD)

Attitudes Affective
(HEART) domain

Skills Psychomotor
(HANDS) Domain

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