Stability/Capability II:  Changeover Reduction & Total Productive Maintenance

As an organization begins to demonstrate fundamental operating discipline, opportunities to reduce equipment changeover losses and improve equipment operating condition become logical and crucial steps in the Lean Journey.  Both Changeover Reduction and Total Productive Maintenance are key enablers towards operating in a flexible and predictable manner, typically resulting in more production capacity, delivery flexibility, better quality, and less inventory.

Through Changeover Reduction, participants will learn the benefits of reduced changeover, when to apply changeover reduction, how to engage the workforce, and the techniques to significantly reduce changeover losses.  The approach will cover key concepts of internal and external work as well as ways to deal with potentially costly material losses due to changeover.

Developing the workforce to participate in the ownership of equipment to eliminate defects, improve safety, and reduce breakdowns is the primary objective of Total Productive Maintenance.  This module will teach participants how to measure Overall Equipment Effectiveness (O.E.E), involve the workforce through group activities, create standardized maintenance routines, and develop autonomous maintenance techniques.