Total Productive Maintenance And Reliability

(1)

I N D U S T R I A L E N G I N E E R I N G P R O G R A M COURSE TITLE: TOTAL PRODUCTIVE MAINTENANCE AND RELIABILITY (TPM)

2nd Semester, Curriculum Year 2018-2019

Holy Angel University VMs

Vision: To become a role-model catalyst for countryside development and one of the most influential, best-managed Catholic universities in the Asia-Pacific region.

Mission: To offer accessible quality education that transforms students into persons of conscience, competence, and compassion.

School of Engineering and Architecture VMs Vision

A center of excellence in engineering and architecture education imbued with Catholic mission and identity serving as a role-model catalyst for countryside development

Mission

The School shall provide accessible quality engineering and architecture education leading to highly competent professional; continually contribute to the advancement of knowledge and technology through research activities; and support countryside development through environmental preservation and community involvement.

Institutional Student Learning Outcomes (ISLOs) 1. Show effective communication

2. Demonstrate appropriate value and sound ethical reasoning 3. Apply critical and creative thinking

(2)

4. Utilize civic and global learning

5. Use applied and collaborative learning 6. Employ aesthetic engagement

7. Show Information and Communication Technology (ICT) Literacy Program Educational Objectives (PEOs)

Within a few years after graduation, graduates of our BS Industrial Engineering programs are expected to have:

1. Demonstrated technical competence, including design and problem-solving skills, as evidenced by:

 the sound technical designs and systems that conform with existing laws and ethical standards they produced

 the recognition and certification they received for exemplary achievement 2. Shown a commitment to life-long learning as evidenced by:

 the graduate degrees or further studies they pursue

 the professional certifications which are locally and internationally recognized they possess

 the knowledge and skills on recent technological advances in the field they continuously acquire 3. Exhibited success in their chosen profession evidenced by:

 the key level positions they hold or promotions they get in their workplace

 the good track record they possess

 the professional visibility (e.g., publications, presentations, patents, inventions, awards, etc.) they are involved with

 the international activities (e.g., participation in international conferences, collaborative research, employment abroad, etc.) they are engaged with

 the entrepreneurial activities they undertake 4. Manifested faithful stewardship as evidenced by:

 their participation in University-based community extension initiatives as alumni

 their contribution to innovations/ inventions for environmental promotion and preservation, and cultural integration

 their engagement in advocacies and volunteer works for the upliftment of the quality of life and human dignity especially the marginalized

(3)

Relationship of the Program Educational Objectives to the Mission of the School of Engineering & Architecture:

Industrial Engineering Program Educational Objectives (PEOs):

Within a few years after graduation, the graduates of the BS Industrial Engineering program should have:

Mission The School shall provide

accessible quality

engineering and architecture education leading to high professional competence.

The School shall continually contribute to the

advancement of knowledge and technology through research activities.

The School shall support countryside development through environmental preservation and community involvement.

1. Demonstrated professional competence, including design and problem solving skills as evidenced by:

 the sound technical designs and systems that conform with existing laws and ethical standards they produced

 the recognition and certification they received for exemplary achievement



2. Shown a commitment to life-long learning evidenced by:

 the graduate degrees or further studies they pursue

 the professional certifications which are locally and internationally recognized they possess

 the knowledge and skills on recent technological advances in the field they continuously acquire



3. Exhibited success in their chosen profession evidenced by:

 the key level positions they hold or promotions they get in their workplace

 the good track record they possess

 the professional visibility (e.g., publications, presentations, patents, inventions, awards, etc.)

 they are involved with international activities (e.g., participation in international conferences, collaborative research, employment abroad, etc.)

 they are engaged with the entrepreneurial activities they undertake

 

4. Manifested faithful stewardship evidenced by: 

(4)

 their participation in University-based community extension initiatives as alumni

 their contribution to innovations/ inventions for environmental promotion and preservation, and cultural integration

 their engagement in advocacies and volunteer works for the upliftment of the quality of life and human dignity especially the marginalized

Relationship of the Institutional Student Learning Outcomes to the Program Educational Objectives:

PEO 1 PEO 2 PEO 3 PEO 4

ISLO1: Show effective communication  

ISLO2: Demonstrate appropriate value and sound ethical reasoning  

ISLO3: Apply critical and creative thinking   

ISLO4: Utilize civic and global learning  

ISLO5: Use applied and collaborative learning    

ISLO6: Employ aesthetic engagement  

ISLO7: Show Information and Communication Technology (ICT) Literacy   

(5)

BS Industrial Engineering Program Outcomes (POs) After finishing the program students will be able to:

a. Apply knowledge of mathematics, physical sciences, and engineering sciences to the practice of Industrial Engineering.

b. Design and conduct experiments, as well as to analyze and interpret data.

c. Design a system, component, or process to meet desired needs within realistic constraints such as economic, environmental, social, political, ethical, health and safety, manufacturability, and sustainability, in accordance with standards.

d. Function on multidisciplinary teams.

e. Identify, formulate and solve engineering problems.

f. Have an understanding of professional and ethical responsibility.

g. Demonstrate and master the ability to listen, comprehend, speak, write and convey ideas clearly and effectively, in person and through electronic media to all audiences.

h. Have broad education necessary to understand the impact of engineering solutions in a global, economic, environmental, and societal context.

i. Recognition of the need for, and an ability to engage in life-long learning and to keep current of the development in the field.

j. Have knowledge of contemporary issues.

k. Use the techniques, skills, and modern engineering tools necessary for engineering practice.

l. Have knowledge and understanding of engineering and management principles as a member and leader in a team, to manage projects and in multidisciplinary environments.

m. Engage in service-learning program for the promotion and preservation to local culture and tradition as well as to the community.

n. Design, develop, implement and improve integrated systems that include people, materials, information, equipment and energy.

Relationship of the Engineering Program Outcomes to the Program Educational Objectives:

Industrial Engineering Student Outcomes (SOs)

At the time of graduation, BS Industrial Engineering program graduates should be able to: PEO 1 PEO 2 PEO 3 PEO 4 a. Apply knowledge of mathematics, physical sciences, and engineering sciences to the practice of

Industrial Engineering. 

b. Design and conduct experiments, as well as to analyze and interpret data. 

(6)

c. Design a system, component, or process to meet desired needs within realistic constraints such as economic, environmental, social, political, ethical, health and safety, manufacturability, and

sustainability, in accordance with standards. 

d. Function on multidisciplinary teams. 

e. Identify, formulate and solve engineering problems. 

f. Have an understanding of professional and ethical responsibility. 

g. Demonstrate and master the ability to listen, comprehend, speak, write and convey ideas clearly

and effectively, in person and through electronic media to all audiences. 

h. Have broad education necessary to understand the impact of engineering solutions in a global,

economic, environmental, and societal context. 

i. Recognition of the need for, and an ability to engage in life-long learning and to keep current of the

development in the field. 

j. Have knowledge of contemporary issues. 

k. Use the techniques, skills, and modern engineering tools necessary for engineering practice. 

(7)

l. Have knowledge and understanding of engineering and management principles as a member and

leader in a team, to manage projects and in multidisciplinary environments. 

m. Ability to design, develop, implement and improve integrated systems that include people,

materials, information, equipment and energy. 

n. Engage in service-learning program for the promotion and preservation to local culture and tradition

as well as to the community. 

Code Descriptor Description

I Introductory Course An introductory course to an outcome

E Enabling Course A course that strengthens the outcome

D Demonstrative Course A course demonstrating an outcome Course Outcomes (COs)

1. Learn, understand and apply the Total Productive Maintenance and Reliability in connection with Total Quality Management in industry setup.

a b c d e f g h i j k l m n

CO1.Learn, understand and apply the Total Productive Maintenance and Reliability in connection with Total Quality Management in industry

setup; E E

I. Course Description : A systematic approach to improving production and quality systems, total productive maintenance (TPM) involves all

employees through a moderate investment in maintenance. This subject highlights the importance of effective communication on all levels to successful TPM implementation. It also discusses the role of the right set of tools from the right perspective—

and demonstrates how to obtain a healthy balance of both.

II. Course Credit : 3 Units

III. Prerequisite : 4th Year Standing

(8)

IV. Textbook : Agustiady, T. (2015).Total productive maintenance : strategies and implementation guide.Boca Raton: CRC Press.

V. Requirements : Recitation Assignment Case Study

Oral Presentation and Defense Written Exams

VI. Learning Outline Week/

Hours

CodeCO

Link Learning Output Student

Output Topics / Course Content Core values

Sub valuesand Methodology Evaluation/

Learning Assessment 1 hourWk 1 At the end of course

or topic the student will be able to:

Learn the importance of subject through the course outcomes

Recognize the different classroom policies

Get familiarized with and use the online learning platforms to be used in class

TPM Subject Orientation

Course outcomes Classroom policies

Attendance

Assignments

Quizzes and major examinations

Case studies

Critique

Subject final output requirement

Grading System

Academic Dishonesty Online Learning Platform

Canvas LMS

Zoom Cloud Meetings

Christ-

centeredness Indicators:

Obedience and prayerfulness Excellence Indicators:

Competence, expertise, analytical, and logical

Societal responsibility Indicators:

Commitment andInvolvement

 Subject orientation conducted by teacher.

(9)

Wk 1-2

3 hours CO1 At the end of course or topic the student will be able to:

Trance the evolution of Total Quality Management from inspection-based quality control to building-in and managing-in quality from design

assurance to product assurance.

Put in the right perspective the different elements of TQM leading to business excellence.

Seatwork

Assignment

Written exam

Case Study

Critique

TQM: Evolution, Models and Frameworks

Evolution of Total Quality Management

Total Quality Loop- Existing Work on Total Quality and Total Quality Management

Classical Approaches to Total Quality Management

Developed Models of Total Quality Management

The Contemporary Total Quality Management and Business Excellence Models: Quality Assessment-based Frameworks

Christ-

Community Indicators:

Solidarity and Respect for others Integrity Indicators:

Accountability,

Transparency and Honesty Societal responsibility Indicators:

Media-supported lecture/ PowerPoint presentation

Class discussions by teachers and

students (face-to- face/online)

Interactive student- centered activities like Think-Pair-Share, Brainstorming, Buzz Session etc.

Hands-on

demonstrations and exercises/ problem

setsCoaching (special assistance provided for students learning difficulty in the course)

Recitation

Written examinations

Alternative summative assessments (reflection papers/

critical analysis)

Asynchronous

teaching and learning using Canvas LMS Platform in providing offline content

resources (readings, lecture notes,

Answer Key

Assessment Rubric is to be used for theevaluation of theclassroom activities

(10)

recorded lectures, detailed guides, etc., in print or digital format) and other activities.

Synchronous

teaching and learning through webinars, live broadcasts, chats and teleconferences for real-time teacher- student engagement.

Wk 2 - 3

Appreciate the basic design and

specifications concepts and their role and impact on

TQM.Appreciate the role of measurement system assessment in TQM.

Understand the use of tools used in TQM Practice.

Explore and identify measures of design quality.

Seatwork

Assignment

Written exam

Case Study

Critique

TQM and Design

Basic Design Concepts and Total Quality Management

Measurement System Evaluation

Design Assurance and Total Quality Management

Design Validation and Review

Failure Models and Effects Analysis and Fault Tree Analysis

Design for Robustness – Taguchi’s Approach

Basic Statistical Concepts

Testing of Hypothesis

Normal Distribution

The t-distribution

The Chi-square Distribution

The F-test

Basic Terms and Definitions of Design of Experiments

Christ-

Accountability,

Hands-on

Recitation

Answer Key

(11)

Completely Randomized Design

Randomized Block Design (RBD)

Factorial Designs

Fractional Factorials

Examples of Applications of Design of Experiments

Benchmarking

Value Analysis

The Design for Six Sigma Approach

Measures of Design Quality

critical analysis)

Asynchronous

Synchronous

3 hoursWk 4 CO1 At the end of course or topic the student will be able to:

Appreciate the role of human resources in organization, leadership and strategic

management for

Seatwork

Assignment

Written exam

Case Study

Critique

TQM and Organization

The Japanese Versus American Approach

The Humanistic Aspects of Total Quality Management

Quality Leadership

Christ-

Competence,

Interactive student- centered activities

Answer Key

Assessment Rubric is to be used for theevaluation of theclassroom

(12)

TQM. expertise, analytical, and logical

Accountability,

like Think-Pair-Share, Brainstorming, Buzz Session etc.

Hands-on

Recitation

critical analysis)

Asynchronous

Synchronous

teaching and learning through webinars, live broadcasts, chats and teleconferences

activities

(13)

for real-time teacher- student engagement.

3 hoursWK 5 CO1 At the end of course or topic the student will be able to:

Appreciate the significance and role of ‘building-in’ TQ through sourcing.

Configure out and develop a well- developed quality information system.

Develop the need to integrate vendor- qualification and vendor-development program.

Critically analyze the issue of TQM from a supply chain point of view.

Seatwork

Assignment

Written exam

Case Study

Critique

TQM and Purchasing and Supply Management

Sourcing Total Quality

Lead Time Reduction with Suppliers

Process Improvement with Suppliers

Continuous Improvement with Suppliers

Supplier Quality Information System

Vendor Qualification and Vendor Development Program

Total Quality and Supply Chain

Christ-

Accountability,

Hands-on

Recitation

critical analysis)

Asynchronous

teaching and learning using Canvas LMS

Answer Key

(14)

Platform in providing offline content

Synchronous

6 P R E L I M E X A M I N A T I O N

3 hoursWk 7 CO1 At the end of course or topic the student will be able to:

Appreciate the meaning, need and scope of SPC in- process quality planning, controlling and improvement from TQM’s point of view.

Understand and signify the role of process quality in better design, planning, monitoring and control of quality

Seatwork

Assignment

Written exam

Case Study

Critique

Statistical Process Control

Sources of Variation

Statistical Process Control

Process Capability

Acceptance Sampling

Christ-

Solidarity and Respect for

Hands-on

setsCoaching (special

Answer Key

(15)

through online

approach. others

Integrity Indicators:

Accountability,

assistance provided for students learning difficulty in the course)

Recitation

critical analysis)

Asynchronous

Synchronous

WK 8-9

Comprehend the

Seatwork

Assignment

Written exam

Case Study

The Six Sigma Approach

Six Sigma Approach:

Various Definitions

Six Sigma: The Statistical

Christ-

Obedience and

Class discussions by

Answer Key

Assessment Rubric is to

(16)

role of Six Sigma approach in both strategic business and operational processes improvement.

Study and delve into statistical thinking and basis of Six Sigma.

Understand metrication of deliverables of the Six Sigma

Approach.

Capture the

operational benefits reaped in corporate post-Six Sigma implementation.

Critique Basis

The Six Sigma Metrics

Cost of Quality

Six Sigma Tools and Implementation Methodologies

The DMAIC Methodology

The DFSS / DMADV Methodology

Six Sigma Roles and Responsibilities

Business Results Post Implementation of Six Sigma

prayerfulness Excellence Indicators:

Accountability,

teachers and students (face-to- face/online)

Hands-on

Recitation

critical analysis)

Asynchronous

be used for theevaluation of theclassroom activities

(17)

Synchronous

Wk 9-10

Appreciate the functional linkages between AMT and systems and TQM for attaining global competitiveness.

Appraise the role of TPM in

implementation of TQM and how it can go a long way.

Ensure a Total Safety culture in an organization.

How TPM can be implemented in an integrated manner with TQM using the eight pillar model.

Seatwork

Assignment

Written exam

Case Study

Critique

TQM and Advanced

Manufacturing Technology and Systems

Advanced Manufacturing Technology

Total Quality Management and Total Preventative Maintenance

Total Quality Management and Total Safety Systems

Total Quality Management and Just in Time

Total Quality Management and Lean Production

Christ-

Accountability,

Transparency and Honesty Societal responsibility

Hands-on

Recitation

Answer Key

(18)

Indicators:

critical analysis)

Asynchronous

Synchronous

Wk 11

To appreciate the role of a customer as the ultimate inspector of quality.

To acknowledge the role of TQM in services.

Seatwork

Assignment

Written exam

Case Study

Critique

TQM and the Customer

Customer: The Ultimate Inspector

Customer Satisfaction Measurements

Some Customer

Satisfaction Determinants

Total Quality Management and Product Liability

Total Quality Management in Services

Christ-

Community

Hands-on

demonstrations and

Answer Key

(19)

Indicators:

Accountability,

exercises/ problem

Recitation

critical analysis)

Asynchronous

Synchronous

12 M I D T E R M E X A M I N A T I O N

(20)

Wk 13

The role of Q-7 and new Q-7 Tools in translating customer requirements.

Seatwork

Assignment

Written exam

Case Study

Critique

Toolkit for TQM

Q-7 Tools

New Q-7 Tools

Quality Function Development

Christ-

Accountability,

Hands-on

Recitation

critical analysis)

Asynchronous

Answer Key

(21)

Synchronous

Wk 14-15

Draw comparisons between QMS and TQM based

approaches to manage quality.

Appreciate the origination and understand the implications of ISO 9000 systems.

Seatwork

Assignment

Written exam

Case Study

Critique

Quality Management System

Difference Between USO 9000 and Total Quality Management Approaches

Quality Management System

ISO 9000: General

The ISO 9000 (Revised):

Standards

The QS-9000 System

Quality Audits

Christ-

Accountability,

Hands-on

Recitation

Answer Key

(22)

critical analysis)

Asynchronous

Synchronous

Wk 16-17

Appreciate the need and significance of QMS with

environment and OHSAS systems.

Grasp the

Seatwork

Assignment

Written exam

Case Study

Critique

Concurrent Implementation of QMS, EMS and OHSAS:

Integrated Management System

The Environmental

Management System; ISO 14000 Standards

BCMS – Business Continuity Management

Christ-

Competence,

Interactive student- centered activities

Answer Key

Assessment Rubric is to be used for theevaluation of theclassroom

(23)

methodology of techniques for hazard analysis such as hazard and operability study and hazard analysis and critical control point.

Appreciate the benefits of concurrent

implementation of QMS with TPM, EMS and OHSAS.

System

Information Security System Standards; ISO 27001

Social Accountability Standards (SA 8000)

WHO- GMP Standards

Hazard and Operability Study and Hazard Analysis and Critical Control Point

Concurrent Implementation of QMS, EMS and OHSAS with Total Preventive Maintenance

A Case for Unification of Safety, Health,

Environment, Maintenance and Quality Management Systems

expertise, analytical, and logical

Accountability,

like Think-Pair-Share, Brainstorming, Buzz Session etc.

Hands-on

Recitation

critical analysis)

Asynchronous

Synchronous

teaching and learning through webinars, live broadcasts, chats and teleconferences

activities

(24)

for real-time teacher- student engagement.

18 F I N A L E X A M I N A T I O N

References:

Agustiady, T. (2015).Total productive maintenance : strategies and implementation guide.Boca Raton: CRC Press.

Online References:

HAU Books 24x7 AccessEngineering EBSCO

(25)

Expectations from Students

Students are held responsible for meeting the standards of performance established for each course. Their performance and compliance with other course requirements are the bases for passing or failing in each course, subject to the rules of the University. The students are expected to take all examinations on the date scheduled, read the assigned topics prior to class, submit and comply with all the requirements of the subject as scheduled, attend each class on time and participate actively in the discussions.

Furthermore, assignments such as reports, reaction papers and the like shall be submitted on the set deadline as scheduled by the faculty. Extension of submission is approved for students with valid reasons like death in the family, hospitalization and other unforeseen events. Hence, certificates are needed for official documentation. Students assigned by the University in extracurricular activities (Choral, Dance Troupe and Athletes) are excused from attending the class, however, said students are not excused from classroom activities that coincide the said University activities. Special quiz is given to students with valid reasons like death in the family, hospitalization and other unforeseen events. Hence, certificates are needed for official documentation. Likewise, special major examination is given to students with the same reasons above. Attendance shall be checked every meeting. Students shall be expected to be punctual in their classes. And observance of classroom decorum is hereby required as prescribed by student’s handbook.

Academic Integrity

It is the mission of the University to train its students in the highest levels of professionalism and integrity. In support of this, academic integrity is highly valued and violations are considered serious offenses. Examples of violations of academic integrity include, but are not limited to, the following:

1.Plagiarism– using ideas, data or language of another without specific or proper acknowledgment. Example: Copying text from the Web site without quoting or properly citing the page URL, using crib sheet during examination. For a clear description of what constitutes plagiarism as well as strategies for avoiding it, students may refer to the HAU Student Handbook 2019-2020, Table of Offenses and Corresponding Sanctions B.7. For citation styles, students may refer to APA Style 6th Edition.

2.Cheating – using or attempting to use unauthorized assistance, materials, or study aids during examination or other academic work. Examples: using a cheat sheet in a quiz or exam, altering a grade exam and resubmitting it for a better grade. For the Policy in Cheating, students may refer to the HAU Student Handbook 2019-2020, Appendix I.

3.Fabrication– submitting contrived or improperly altered information in any academic requirements. Examples: making up data for a research project, changing data to bias its interpretation, citing nonexistent articles, contriving sources. Student may refer to HAU Student Handbook 2019-2020, Table of Offenses and Corresponding Sanctions B.7.

(26)

Policy on Absences

1. Students should not incur absences of more than 20% of the required total number of class and laboratory periods in a given semester.

a. The maximum absences allowed per semester are:

For subjects held 1x a week, a maximum of 3 absences;

For subjects held 2x a week, a maximum of 7 absences; and For subjects held 3x a week, a maximum of 10 absences.

2. A student who incurs more than the allowed number of absences in any subject shall be given a mark of “FA” as his final rating for the semester, regardless of his performance in the class.

3. Attendance is counted from the first official day of regular classes regardless of the date of enrolment.

Other Policies

 Departmentalized when it comes to major exams such as Prelim, Midterms and Finals.

 Minimum of two (2) quizzes for every one (1) unit course will be given per semester.

 Drills, Exercises, Seat works, Projects, Recitation/Role playing will be given to the students and will be graded as part of class standing.

 Homework Policy will be given at the discretion of the faculty and will be graded as part of class standing.

Grading System (Campus ++):

Class Standing: 60%

 Recitation

 Homework

 Quizzes Major Exams: 40%

DatePrepared: Date

Effectivity: Prepared By: Reviewed By: Checked By: Certified By: Approved By:

May 2020 May 2020

Calvin Karl R.

Garganta, CIE, Assoc. ASEAN Eng

Faculty

Engr. Ruselle Andrew P. Manalang

OBE Facilitator

Melani B. Cabrera, PIE Chairperson, Industrial

Engineering Program

Dr. Bonifacio V. Ramos Director,

University Library

Dr. Filipina I. De Guzman Dean, School of Engineering

and Architecture