Tpm for the Lean Factory

by Arai; Keisuke

• ISBN13: 9781563271915
• ISBN10: 1563271915
• Format: Hardcover
• Copyright: 1998-09-24
• Publisher: Productivity Pr

Summary

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 Factoryextends a fresh vision and focus to help you get top results from your TPM efforts.

Table of Contents

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