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

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Title: TPM for the Lean Factory : Innovative Methods and Worksheets for Equipment Management
Author: Keisuke Arai, Kenichi Sekine
ISBN: 1498767400 / 9781498767408
Format: Hard Cover
Pages: 360
Publisher: Productivity Press
Availability: In Stock
Special Indian Edition Priced at Rs.2895/-. FREE Shipping within India. Delivery : Within 2 to 4 working days.
     
 
  • Description
  • Contents

Lean manufacturing cannot happen in a factory that lacks dependable, effective equipment. Breakdowns and processing defects translate into excess work-in-process and finished inventory, kept on hand "just in case." Recurring minor stoppages force employees to watch automated equipment that should run by itself. TPM gives a framework for addressing such problems, but many companies implement TPM at a superficial level, and the resulting productivity gains fall short of their potential. If your TPM implementation has resulted in posters and logos rather than a rise of productivity, how are you addressing this halt of progress? In TPM for the Lean Factory, authors Sekine and Arai teach you to identify and attack the key equipment-related problems and misunderstandings that make plants miss their lean manufacturing goals.

Written for companies with a basic TPM framework already in place, you'll learn three powerful approaches for cutting this waste:

  • The new 5Ss: focusing on standard locations and labeling through the first 2Ss
  • Instant maintenance: mastering quick repairs of minor equipment failures
  • Improved setup operations: organizing the preparation to save time and prevent errors

Chapters on cell design, product and process quality factor testing, and daily equipment inspection give you additional weapons for fighting waste and low productivity. For practical application, an implementation overview summarizes the steps for each topic, keyed to a set of 50 adaptable worksheets and examples. A practical and supportive resource, TPM for the Lean Factory extends a fresh vision and focus to help you get top results from your TPM efforts.

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

Chapter 2 : The 5S's Begin with 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
  • 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
  • A New Way of Thinking about the 5Ss
  • Mynac's 5S Know-How : The Ten Principles
  • Steps for Interesting and Enjoyable 5S Activities
  • 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
  • Step 4 : Form a Clear Picture of the Phenomenon, Mechanisms, and Causes Apply Why-Why Analysis
  • Step 5 : Set Up an Instant Maintenance System
  • 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
  • Step 6 : Demonstrate the Maintenance Techniques to Employees

Chapter 6 : Improving Setup Operations

  • A Well-Done Setup Can Demonstrate the Effectiveness of TPM
  • Seven Causes of Aimless and Disorganized Setup
  • Work Machining Diagrams without Standards
  • Programming without Standards
  • Machines without Positioning Standards (Machines with Variable Processing Standards)
  • Steps for Improving Setup

Chapter 7 : Eliminating the Waste of Planned Downtime

  • Excessive Planned Downtime
  • Razing the Old Line to Build Something New Test Yourself
  • Steps for Process Design

Chapter 8 : Eliminating Abnormalities within the Process

  • Example : Decreasing Soldering Defects in Printed Circuit Boards
  • Testing for Optimal Conditions for Circuit Board Soldering

Chapter 9 : Promoting Daily Equipment Inspections

  • Introducing Daily Inspections and Implementing a Program
  • Eliminating Minor Stoppages
  • Using Sensory Inspection to Detect Machine and Equipment Abnormalities
  • Examples of Small-Scale Improvements
  • Daily Inspection Charts

Chapter 10 : Test Yourself : A Lean TPM Quiz

  • Question 1 : Discipline as the Focus of the 5Ss
  • Question 2 : The Operators 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

Implementing Overview for TPM Innovation
Worksheets for TPM Innovation
References
About the Authors
Index

 
 
 
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