In a reliability-based culture, a strong partnership is leveraged between the Operations, Maintenance, and Engineering organizations to achieve a common production goal. Operator Care programs begin with a focus on improving the work environment for the Operator. Analyzing production performance with problem solving tools helps identify waste and opportunities to stabilize the operation with standardized work and asset control strategies. This 3-day course defines the concept of Operator Care as part of a broader Reliability Program, and introduces the tools operators can utilize to meet and exceed production goals. Participants will discuss examples and case studies to gain understanding of, and apply a successful Operator Care Program. During this course, participants will also be introduced to lean manufacturing methodologies including: value stream mapping, 5S, standardized work, and problem solving. The course focuses on making data-driven decisions to create effective Operator Care tasks, manage work balance between organizations, and achieve operational stability through continuous improvement.

1. 1© Life Cycle Institute© Life Cycle Institute
Operator Care – A Program for Reliability
Engage People, Reduce Risk and Improve Performance

2. 2© Life Cycle Institute
Operator Care: Engage the Workforce
Effort
driven by
operations
Build skills
and
capabilities
Reduce
waste and
eliminate
problems
Improve
safety,
quality and
reliability

3. 3© Life Cycle Institute
Learning Objectives
1. Explain how an Operator Care (OC) program improves production
performance and asset reliability
2. Tailor the benefits of an OC program to reach stakeholders
3. Assess your organization’s readiness to implement an OC program
4. Use the TPM and Rx models to inform your OC program design
5. Draft a single point lesson
6. Use a skills matrix to assess and plan for training & skill
development
7. Outline OC program installation key concepts, critical success
factors
8. Create an action plan for OC program goals, setup and execution

4. 4© Life Cycle Institute
Course Details
• 3-day class
• Private, onsite classes
• 2.1 CEUs

5. 5© Life Cycle Institute
Why Operator Care with Life Cycle Institute?
Instructors are qualified content experts and trained facilitators
of learning
– They apply the content they teach
– They complete a rigorous facilitator qualification and
certification process
• Focus on the process of learning and transfer to the job
• Engage learners, reinforce relevancy and integrate prior
experience
The training program is an active experience of learning by doing
vs. lecture
– Group activities, assessments, case studies
– Network with peers
Participants develop action plans to support learning and results

6. 6© Life Cycle Institute
LCE Approach to Operator Care
• Focus on the 4 elements of Operator Care
• Based on Reliability Excellence® and TPM
• Start with goals, metrics, monitor progress
• Includes standards and templates
• End with A3 report and plan for a successful
Operator Care program

7. 7© Life Cycle Institute
Know Your Machine and Process (KYMP):
OC Element 1
• Understanding losses
from ideal
• Measure OEE
• Visual workplace
• Equipment mini-
manual

8. 8© Life Cycle Institute
Prevent and Postpone (P2): OC Element 2
• How machines fail
• Equipment life stages
• TLC: tighten,
lubricate, clean
• Return like new
• Cleaning standards
• SPL: single point
lessons

9. 9© Life Cycle Institute
Detect Defects, Diagnose and Report (D3R):
OC Element 3
• Inspection
requirements and
standards
• Defect tagging and
tracking
• Visual management
(progress boards)

10. 10© Life Cycle Institute
Continuous Improvement (CI): OC Element 4
• Lean maintenance
• Root cause analysis
and countermeasures
• Installing OC:
– Assess
– Manage
– Motivate

11. 11© Life Cycle Institute
4 Elements of Operator Care
KYMP P2
D3R CI

12. 12© Life Cycle Institute
Operator Care is available as
a private class.
education@LCE.com
www.LCE.com
800-556-9589