TPM for the Lean Factory : Innovative Methods and Worksheets for Equipment Management

Publisher's Message xi(4) Preface xv Chapter 1 The Seven Types of Waste in TPM 1(12) Why TPM Now? 1(1) The Seven Types of Waste 2(1) Defining and Eliminating Waste 3(10) Waste Due to Stoppages 3(1) Minor Stoppages 4(1) Medium and Major Stoppages 5(1) Waste Due to Long Setup Times 6(1) Waste Due to Rework, Defects, Faulty Products, and Low Yields 7(1) Waste Due to Planned Downtime 8(1) Waste Due to Incomplete 2S Application 9(1) Waste Due to Overproduction by Large Equipment 10(1) Waste Due to Equipment Problems at Production Startup 10(1) Test Yourself 10(1) Our Answers 10(3) Chapter 2 The 5Ss Begin with the 2Ss 13(12) Proclaiming the New 5Ss 13(1) 5S Means More Than Posters on the Wall 14(1) Discipline Is the Heart of 5S 15(1) Implementing the 2Ss for the Pre-Setup Stage 16(6) Steps for Eliminating Waste in Pre-Setup 19(1) Step 1. Getting a Grasp of the Current Situation 19(1) Step 2. Making On-Site Observations 20(1) Step 3. Eliminating Waste in Searching 20(1) Step 4. Designing the Layout of the Pre-Setup Line 21(1) Step 5. Putting the Principles to Work on the Spot 21(1) Step 6. Documenting the Results 21(1) Maintaining Improved Conditions 22(1) Benefits of Proper 2S Implementation 22(3) Chapter 3 A New 5S Example: Mynac Company Case Study 25(24) The 5Ss Have Become the Jive Ss 25(1) Successful 5S Application Requires Serious and Methodical Top Managers 26(2) The 5Ss at Mynac 26(2) A New Way of Thinking about the 5Ss 28(2) Mynac's 5S Know-How: The Ten Principles 30(8) Steps for Interesting and Enjoyable 5S Activities 38(5) Step 1: Announcing the Program from the Top 38(1) Step 2: Determining the Inspection Sequence 38(1) Step 3: Sweating Out the Grime 38(1) Step 4: Determining the Extent of the Problems 38(2) Step 5: Labeling the Worst Problem 40(1) Step 6: Working to Remove the Label 40(1) Step 7: Confirming That All the "Grime" Has Been Removed 40(2) Step 8: Setting Up Standard Storage Locations with Standard Labels 42(1) Step 9: Creating 2S Production Lines 42(1) Methods for Maintaining the 5Ss as a System 43(6) Chapter 4 The Fundamentals of Instant Maintenance 49(16) Step 1. Study Current Conditions 49(4) Step 2: Summarize the Problems with Each Line and Machine 53(1) Step 3: Analyze Minor Stoppage Mechanisms and Their Causes 53(3) Confirm the Situation 53(3) Analyze the Mechanism and Make a Hypothesis about the Cause 56(1) Step 4: Form a Clear Picture of the Phenomenon, Mechanisms, and Causes 56(1) Apply Why-Why Analysis 56(1) Step 5: Set Up an Instant Maintenance Items 56(3) Educate People about Instant Maintenance Items 56(1) Designate Major Maintenance Items 56(3) Step 6: Provide Support for Autonomous Maintenance Activities 59(2) Step 7: Create Instant Maintenance Manuals and Demonstrate Techniques 61(4) Chapter 5 A Case Study in Instant Maintenance 65(20) Step 1: Study Current Conditions 65(1) Step 2: Summarize the Problems with Each Line and Machine 65(2) Step 3: Analyze Stoppage Mechanisms and Hypothesize Causes 67(1) Step 4: Form a Clear Picture of the Phenomenon, Mechanisms, and Causes 67(6) Apply Why-Why Analysis 67(6) Step 5: Set Up an Instant Maintenance System 73(4) Determine Instant Maintenance Parts 73(1) Develop a Two-Bin System for Parts 73(3) Create Instant Maintenance Sheets 76(1) Practice the Maintenance Routines 76(1) Step 6: Demonstrate the Maintenance Techniques to Employees 77(8) Chapter 6 Improving Setup Operations 85(18) A Well-Done Setup Can Demonstrate the Effectiveness of TPM 85(1) Seven Causes of Aimless and Disorganized Setup 85(3) Pre-Setup without Standards 86(1) Jig and Mold Replacement without Standards 86(2) Test Yourself 88(1) Our Answers 88(1) Work Machining Diagrams without Standards 88(4) Blade Replacement without Standards 90(1) Improving Chucks 90(2) Programming without Standards 92(1) Machines without Positioning Standards (Machines with Variable Processing Standards) 92(3) Test Yourself 93(1) Our Answer 93(1) Cleanup without Standards 94(1) Problems 94(1) Steps for Improving Setup 95(8) Step 1: Study Current Setup Losses 96(1) Step 2: Form Setup Improvement Promotion Team 96(1) Step 3: Perform On-Site Observation and Operation Analysis 97(1) Step 4: Apply Waste Elimination Concepts 98(2) Step 5: Deploy Improvement Plans 100(2) Step 6: Implement Improvements 102(1) Step 7: Evaluate and Spread Horizontally 102(1) Chapter 7 Eliminating the Waste of Planned Downtime 103(16) Excessive Planned Downtime 103(3) Razing the Old Line to Build Something New 106(3) Test Yourself 107(1) Our Answer 107(2) Steps for Process Design 109(10) Step 1. Study Current Conditions 109(1) PQ Analysis 109(2) Process Path Analysis 111(1) Step 2. Eliminate Visible Waste 112(1) Step 3. Pursue the Goals of Process Design 113(2) Step 4. Discover the Trouble Spots 115(1) Step 5. Design a Layout for the New Line 116(1) Step 6. Create the Line and Try Running It 117(2) Chapter 8 Eliminating Abnormalities within the Process 119(70) Example: Decreasing Soldering Defects in Printed Circuit Boards 119(6) Step 1. Study Current Conditions 120(2) Step 2. Create Families of Circuit Boards 122(1) Step 3. Investigate the Primary Factors for Solder Dip Defects 122(1) Step 4: Look for Optimal Conditions While Carrying Out Daily Production 123(2) Testing for Optimal Conditions for Circuit Board Soldering 125(4) Step 1. Perform Experiments for Finding Optimal Conditions 125(1) Step 2. Summarize the Data 125(1) Step 3. Put the Findings into Graphic Form 125(1) Step 4. Identify the Effective Factors and Levels 125(1) Step 5. Estimate the Defect Rate under Optimal Conditions 126(1) Step 6. Test with a Confirmation Experiment 126(3) Chapter 9 Promoting Daily Equipment Inspections 129(50) Introducing Daily Inspections and Implementing a Program 129(5) Step 1. Summarize the Problems at Each Station 129(1) Step 2. Analyze the Breakdown Mechanisms 130(1) Step 3. Implement Measures to Eliminate the Causes 130(1) Step 4. Attach Daily Inspection Labels to Equipment 130(1) Step 5. Divide Parts and Components into Three Groups 130(1) Step 6. Manage the Spare Parts Inventory 130(1) Step 7. Improve Parts Replacement Procedures 130(3) Step 8. Investigate Broken Parts 133(1) Step 9. Thoroughly Train Employees in Daily Maintenance 133(1) Eliminating Minor Stoppages 134(4) Classifying Minor Stoppages 134(1) Why Do Minor Stoppages Occur? 134(1) Why Minor Stoppages Lead to Significant Waste 135(1) How Minor Stoppages Differ from Breakdowns 136(1) Steps for Eliminating Minor Stoppages 136(1) Step 1: Study Current Conditions 136(1) Step 2: Rethink the Process from the Ground Up 136(1) Step 3: Pursue the Goal 136(2) Step 4: Root Out the Causes 138(1) Step 5: Plan Countermeasures 138(1) Step 6: Create an Improvement Plan 138(1) Step 7: Implement the Plan Immediately 138(1) Using Sensory Inspection to Detect Machine and Equipment Abnormalities 138(18) The Operator's Role 139(1) Detecting Abnormalities and Their Symptoms 139(1) Detection by Sight 139(2) Detection by Sound 141(1) Detection by Touch 141(1) Detection by Smell 141(1) Inspection Pointers 141(15) Examples of Small-Scale Improvements 156(2) Daily Inspection Charts 158(2) Daily Inspection Standards for an Electric Motor 160(1) Instant Maintenance Manual for an Assembler 160(1) Daily Inspection Chart for a Mold 160(1) Inspection Items for a Solder Tank 160(1) An Inspection Sheet for an Electronic Device 160(1) Other Inspection Charts 160(19) Test Yourself 161(1) Our Answers 161(18) Chapter 10 Test Yourself: A Lean TPM Quiz 179(24) Question 1. Discipline as the Focus of the 5Ss 180(1) Question 2. The Operator's Role in Machine Life Span 181(1) Question 3. What's Wrong with This Diagram? 182(1) Question 4. Standards for Parts Fitted on a Shaft 182(1) Question 5. Which Senses Detect What Situation? 183(2) Question 6. Avoiding Replacement of Guide Rails During Setup 185(1) Question 7. The Most Practical Type of Chucking Jaws for an NC Lathe 186(1) Question 8. Studying Current Conditions Before Making an Inspection Chart 187(1) Question 9. Which Sentence Does Not Describe a Type of Waste? 188(2) Question 10. How's Your 5S Score? 190(2) Question 11. The Definition of "Design TPM" 192(1) Question 12. The Definition of Value Analysis 192(1) Question 13. Is There Such a Thing as an Economic Lot Size? 193(3) Golf is a Four-Unit Lot, One-Piece Flow Game 196(1) Question 14. Machining Centers and Mass Production 197(6) Implementation Overview for TPM Innovation 203(14) Worksheets for TPM Innovation 217(112) 1. TPM Introduction and Education Planning Sheet 226(2) 2. TPM Team Organization Chart 228(2) 3. TPM Team Meeting Evaluation 230(2) 4. Productivity Diagnosis Deployment Plan 232(2) 5. TPM Survey 234(2) 6. Summary of Improvement Study Group Issues 236(2) 7. TPM Management Board 238(2) 8. Hourly Production Record 240(2) 9. Cumulative Availability, Efficiency Rate, and Quality Rate Chart 242(2) 10. Monthly Summary of Non-Working Time 244(2) 11. Manufacturing Process Planning Sheet (by Machine Model) 246(2) 12. Process Quality Management Chart (General Use) 248(2) 13. Operation Observation Sheet (Work Sampling) 250(2) 14. Line Balance Measurement Sheet 252(2) 15. Main Line Check Sheet 254(2) 16. Malfunction Cause and Treatment Chart 256(2) 17. 5S Evaluation Chart 258(4) 18. Pareto Chart 262(2) 19. Monthly Line Efficiency Report 264(2) 20. Equipment Operation Analysis Chart 266(2) 21. Minor Stoppage Cause Sheet 268(2) 22. Summary of Defects by Line 270(2) 23. Minor Stoppage Analysis Sheet (Hand-Fed Machines) 272(2) 24. Why-Why Analysis 274(2) 25. Equipment Problem-Solving Plan 276(2) 26. Small Tool Improvement Sheet 278(2) 27. Daily Maintenance Sheet 280(2) 28. Instant Maintenance Labels 282(2) 29. Pre-Shift Check Sheet 284(2) 30. Record of Equipment Problems 286(2) 31. Instant Maintenance Sheet (Type 1) 288(2) 32. Instant Maintenance Sheet (Type 2) 290(2) 33. Machining Center Stoppage Cause Sheet 292(2) 34. PM Notes 294(2) 35. P-M Analysis Chart 296(2) 36. Cause and Effect Diagram 298(2) 37. Equipment Maintenance Card 300(2) 38. Sporadic/Planned Equipment Repair Report 302(2) 39. Setup Operation Analysis 304(2) 40. Improvement Deployment Chart 306(2) 41. Standard Work Combination Sheet (Changeover) 308(2) 42. Process Capacity Table 310(2) 43. Standard Work Combination Sheet 312(2) 44. Defect Reduction Activity Chart 314(2) 45. Daily Inspection Chart 316(2) 46. Minor Stoppage Investigation Sheet (Automated Equipment) 318(2) 47. TPM Top Management Diagnosis--Self-Diagnosis Sheet 320(2) 48. Line Improvement Follow-up Sheet 322(2) 49. TPM Team Presentation Evaluation 324(2) 50. TPM Team Line Contest Evaluation 326(3) References 329(2) About the Authors 331(2) Index 333