TPM for the Lean Factory by Sekine, Kenʼichi,Arai, Keisuke -- Read -- Imperial Library of Trantor

Index

Cover Half Title Title Page Copyright Page Table of Contents Publisher’s Message Preface Chapter 1 The Seven Types of Waste in TPM

Why TPM Now? The Seven Types of Waste Defining and Eliminating Waste

Waste Due to Stoppages

Minor Stoppages Medium and Major Stoppages

Waste Due to Long Setup Times Waste Due to Rework, Defects, Faulty Products, and Low Yields Waste Due to Planned Downtime Waste Due to Incomplete 2S Application Waste Due to Overproduction by Large Equipment Waste Due to Equipment Problems at Production Startup Test Yourself Our Answers

Chapter 2 The 5Ss Begin with the 2Ss

Proclaiming the New 5Ss 5S Means More Than Posters on the Wall Discipline Is the Heart of 5S Implementing the 2Ss for the Pre-Setup Stage

Steps for Eliminating Waste in Pre-Setup

Step 1. Getting a Grasp of the Current Situation Step 2. Making On-Site Observations Step 3. Eliminating Waste in Searching Step 4. Designing the Layout of the Pre-Setup Line Step 5. Putting the Principles to Work on the Spot Step 6. Documenting the Results

Maintaining Improved Conditions

Benefits of Proper 2S Implementation

Chapter 3 A New 5S Example: Mynac Company Case Study

The 5Ss Have Become the Jive Ss Successful 5S Application Requires Serious and Methodical Top Managers

The 5Ss at Mynac

A New Way of Thinking about the 5Ss Mynac’s 5S Know-How: The Ten Principles Steps for Interesting and Enjoyable 5S Activities

Step 1: Announcing the Program from the Top Step 2: Determining the Inspection Sequence Step 3: Sweating Out the Grime Step 4: Determining the Extent of the Problems Step 5: Labeling the Worst Problem Step 6: Working to Remove the Label Step 7: Confirming That All the “Grime” Has Been Removed Step 8: Setting Up Standard Storage Locations with Standard Labels Step 9: Creating 2S Production Lines

Methods for Maintaining the 5Ss as a System

Chapter 4 The Fundamentals of Instant Maintenance

Step 1. Study Current Conditions Step 2: Summarize the Problems with Each Line and Machine Step 3: Analyze Minor Stoppage Mechanisms and Their Causes

Confirm the Situation Analyze the Mechanism and Make a Hypothesis about the Cause

Step 4: Form a Clear Picture of the Phenomenon, Mechanisms, and Causes

Apply Why-Why Analysis

Step 5: Set Up an Instant Maintenance System

Educate People about Instant Maintenance Items Designate Major Maintenance Items

Step 6: Provide Support for Autonomous Maintenance Activities Step 7: Create Instant Maintenance Manuals and Demonstrate Techniques

Chapter 5 A Case Study in Instant Maintenance

Step 1: Study Current Conditions Step 2: Summarize the Problems with Each Line and Machine Step 3: Analyze Stoppage Mechanisms and Hypothesize Causes Step 4: Form a Clear Picture of the Phenomenon, Mechanisms, and Causes

Apply Why-Why Analysis

Step 5: Set Up an Instant Maintenance System

Determine Instant Maintenance Parts Develop a Two-Bin System for Parts Create Instant Maintenance Sheets Practice the Maintenance Routines

Step 6: Demonstrate the Maintenance Techniques to Employees

Chapter 6 Improving Setup Operations

A Weil-Done Setup Can Demonstrate the Effectiveness of TPM Seven Causes of Aimless and Disorganized Setup

Pre-Setup without Standards Jig and Mold Replacement without Standards

Test Yourself Our Answers

Work Machining Diagrams without Standards

Blade Replacement without Standards

Improving Chucks

Programming without Standards Machines without Positioning Standards (Machines with Variable Processing Standards)

Test Yourself Our Answer Cleanup without Standards Problems

Steps for Improving Setup

Step 1: Study Current Setup Losses Step 2: Form Setup Improvement Promotion Team Step 3: Perform On-Site Observation and Operation Analysis Step 4: Apply Waste Elimination Concepts Step 5: Deploy Improvement Plans Step 6: Implement Improvements Step 7: Evaluate and Spread Horizontally

Chapter 7 Eliminating the Waste of Planned Downtime

Excessive Planned Downtime Razing the Old Line to Build Something New

Test Yourself Our Answer

Steps for Process Design

Step 1. Study Current Conditions

PQ Analysis Process Path Analysis

Step 2. Eliminate Visible Waste Step 3. Pursue the Goals of Process Design Step 4. Discover the Trouble Spots Step 5. Design a Layout for the New Line Step 6. Create the Line and Try Running It

Chapter 8 Eliminating Abnormalities within the Process

Example: Decreasing Soldering Defects in Printed Circuit Boards

Step 1. Study Current Conditions Step 2. Create Families of Circuit Boards Step 3. Investigate the Primary Factors for Solder Dip Defects Step 4. Look for Optimal Conditions While Carrying Out Daily Production

Testing for Optimal Conditions for Circuit Board Soldering

Step 1. Perform Experiments for Finding Optimal Conditions Step 2. Summarize the Data Step 3. Put the Findings into Graphic Form Step 4. Identify the Effective Factors and Levels Step 5. Estimate the Defect Rate under Optimal Conditions Step 6. Test with a Confirmation Experiment

Chapter 9 Promoting Daily Equipment Inspections

Introducing Daily Inspections and Implementing a Program

Step 1. Summarize the Problems at Each Station Step 2. Analyze the Breakdown Mechanisms Step 3. Implement Measures to Eliminate the Causes Step 4. Attach Daily Inspection Labels to Equipment Step 5. Divide Parts and Components into Three Groups Step 6. Manage the Spare Parts Inventory Step 7. Improve Parts Replacement Procedures Step 8. Investigate Broken Parts Step 9. Thoroughly Train Employees in Daily Maintenance

Eliminating Minor Stoppages

Classifying Minor Stoppages Why Do Minor Stoppages Occur? Why Minor Stoppages Lead to Significant Waste How Minor Stoppages Differ from Breakdowns Steps for Eliminating Minor Stoppages

Step 1: Study Current Conditions Step 2: Rethink the Process from the Ground Up Step 3: Pursue the Goal Step 4: Root out the Causes Step 5: Plan Countermeasures Step 6: Create an Improvement Plan Step 7: Implement the Plan Immediately

Using Sensory Inspection to Detect Machine and Equipment Abnormalities

The Operator’s Role Detecting Abnormalities and Their Symptoms

Detection by Sight Detection by Sound Detection by Touch Detection by Smell Inspection Pointers

Examples of Small-Scale Improvements Daily Inspection Charts

Daily Inspection Standards for an Electric Motor Instant Maintenance Manual for an Assembler

Daily Inspection Chart for a Mold Inspection Items for a Solder Tank An Inspection Sheet for an Electronic Device Other Inspection Charts

Test Yourself Our Answers

Chapter 10 Test Yourself: A Lean TPM Quiz

Question 1. Discipline as the Focus of the 5Ss Question 2. The Operator’s Role in Machine Life Span Question 3. What’s Wrong with This Diagram? Question 4. Standards for Parts Fitted on a Shaft Question 5. Which Senses Detect What Situation? Question 6. Avoiding Replacement of Guide Rails During Setup Question 7. The Most Practical Type of Chucking Jaws for an NC Lathe Question 8. Studying Current Conditions Before Making an Inspection Chart Question 9. Which Sentence Does Not Describe a Type of Waste? Question 10. How’s Your 5S Score? Question 11. The Definition of “Design TPM” Question 12. The Definition of Value Analysis Question 13. Is There Such a Thing as an Economic Lot Size? Golf is a Four-Unit Lot, One-Piece Flow Game Question 14. Machining Centers and Mass Production

Implementation Overview for TPM Innovation Worksheets for TPM Innovation

1. TPM Introduction and Education Planning Sheet 2. TPM Team Organization Chart 3. TPM Team Meeting Evaluation 4. Productivity Diagnosis Deployment Plan 5. TPM Survey 6. Summary of Improvement Study Group Issues 7. TPM Management Board 8. Hourly Production Record 9. Cumulative Availability, Efficiency Rate, and Quality Rate Chart 10. Monthly Summary of Non-Working Time 11. Manufacturing Process Planning Sheet (by Machine Model) 12. Process Quality Management Chart (General Use) 13. Operation Observation Sheet (Work Sampling) 14. Line Balance Measurement Sheet 15. Main Line Check Sheet 16. Malfunction Cause and Treatment Chart 17. 5S Evaluation Chart 18. Pareto Chart 19. Monthly Line Efficiency Report 20. Equipment Operation Analysis Chart 21. Minor Stoppage Cause Sheet 22. Summary of Defects by Line 23. Minor Stoppage Analysis Sheet (Hand-Fed Machines) 24. Why-Why Analysis 25. Equipment Problem-Solving Plan 26. Small Tool Improvement Sheet 27. Daily Maintenance Sheet 28. Instant Maintenance Labels 29. Pre-Shift Check Sheet 30. Record of Equipment Problems 31. Instant Maintenance Sheet (Type 1) 32. Instant Maintenance Sheet (Type 2) 33. Machining Center Stoppage Cause Sheet 34. PM Notes 35. P-M Analysis Chart 36. Cause and Effect Diagram 37. Equipment Maintenance Card 38. Sporadic/Planned Equipment Repair Report 39. Setup Operation Analysis 40. Improvement Deployment Chart 41. Standard Work Combination Sheet (Changeover) 42. Process Capacity Table 43. Standard Work Combination Sheet 44. Defect Reduction Activity Chart 45. Daily Inspection Chart 46. Minor Stoppage Investigation Sheet (Automated Equipment) 47. TPM Top Management Diagnosis—Self-Diagnosis Sheet 48. Line Improvement Follow-up Sheet 49. TPM Team Presentation Evaluation 50. TPM Team Line Contest Evaluation

References About the Authors Index

← Prev
Back
Next →

← Prev
Back
Next →