TPM in Process Industries


Author: Tokutaro Suzuki
Publisher: Routledge
ISBN: 1351407414
Category: Business & Economics
Page: 416
View: 6700

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Process industries have a particularly urgent need for collaborative equipment management systems, but until now have lacked for programs directed toward their specific needs. TPM in Process lndustries brings together top consultants from the Japan Institute of Plant Maintenance to modify the original TPM Development Program. In this volume, they demonstrate how to analyze process environments and equipment issues including process loss structure and calculation, autonomous maintenance, equipment and process improvement, and quality maintenance. For all organizations managing large equipment, facing low operator/machine ratios, or implementing extensive improvement, this text is an invaluable resource.

Autonomous Maintenance in Seven Steps

Implementing TPM on the Shop Floor
Author: Fumio Gotoh,Masaji Tajiri
Publisher: Productivity Press
ISBN: 9781563272196
Category: Business & Economics
Page: 352
View: 8416

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Autonomous maintenance is an especially important pillar of Total Productive Maintenance (TPM) because it enlists the intelligence and skills of the people who are most familiar with factory machines-- equipment operators. Operators learn the maintenance skills they need to know through a seven-step autonomous maintenance program. Most companies in the West stop after implementing the first few steps and never realize the full benefits of autonomous maintenance. This book contains comprehensive coverage of all seven steps--not just the first three or four. It includes: An overview of autonomous maintenance features and checklists for step audits to certify team achievement at each AM step. TPM basics such as the six big losses, overall equipment effectiveness (OEE), causes of losses, and six major TPM activities. An implementation plan for TPM and five countermeasures for achieving zero breakdowns. Useful guidelines and case studies in applying AM to manual work such as assembly, inspection, and material handling. Integrates examples from Toyota, Asai Glass, Bridgestone, Hitachi, and other top companies. By treating machines as partners and taking responsibility for them, you get machines that you can rely on and help maintain an energized and responsive workplace. For companies that are serious about taking autonomous maintenance beyond mere cleaning programs, this is an essential sourcebook and implementation support.

Total Productive Maintenance

Proven Strategies and Techniques to Keep Equipment Running at Maximum Efficiency
Author: Steve Borris
Publisher: McGraw Hill Professional
ISBN: 9780071589260
Category: Technology & Engineering
Page: 448
View: 1243

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Reduce or eliminate costly downtime Short on teory and long on practice, this book provides examples and case studies, designed to provide maintenance engineers and supervisors with a framework for operational strategies and day-to-day management and training techniques that will keep their equipment running at top efficiency.

WCOM (World Class Operations Management)

Why You Need More Than Lean
Author: Carlo Baroncelli,Noela Ballerio
Publisher: Springer
ISBN: 3319301055
Category: Technology & Engineering
Page: 277
View: 1568

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This book deals with World Class Operations Management (WCOM), detailing its principles, methods and organisation, and the results that this approach can bring about. Utilising real-world case studies illustrated by companies that have adopted this model (interviews with Saint-Gobain, L’Oréal, Tetra Pak, Bemis, and Bel Executives), it describes common patterns drawn from decades of hands-on experience, so as to present a theoretical approach together with the concrete application of its principles. WCOM, adopted by several multinational companies, is one of the more innovative management practises, as it integrates the best Continuous Improvement approaches (Lean, Total Productive Management, World Class Manufacturing) as well as the most innovative approaches in human dynamics like Change Leadership, Performance Behavior, Shingo Model, to name a few. Maximising reader insights into the successful implementation of such an approach, and explaining not only its potentialities, but also its implementation dynamics, the critical points and the ways it can be integrated into different situations, this book is also about how to create a culture of excellence that is sustainable over a long period of time and delivers consistent (or ever-improving) results.

Introduction to TPM

Total Productive Maintenance
Author: Seiichi Nakajima
Publisher: N.A
ISBN: N.A
Category: Technology & Engineering
Page: 129
View: 639

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This was the first book in English on total productive maintenance (TPM) - a system which has been shown to reduce breakdowns to almost zero and increase worker productivity by as much as 150 percent.

Total Productive Maintenance

Strategies and Implementation Guide
Author: Tina Kanti Agustiady,Elizabeth A. Cudney
Publisher: CRC Press
ISBN: 1482255405
Category: Business & Economics
Page: 322
View: 6413

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A systematic approach to improving production and quality systems, total productive maintenance (TPM) involves all employees through a moderate investment in maintenance. Therefore, a successful TPM implementation requires support of all employees from C-level on down. Total Productive Maintenance: Strategies and Implementation Guide highlights the importance of effective communication on all levels to successful TPM implementation. It also discusses the role of the right set of tools from the right perspective—and demonstrates how to obtain a healthy balance of both. Authors Tina Agustiady and Elizabeth Cudney recognized a need for better understanding of how to apply and integrate the TPM philosophy and its associated tools and techniques. In this book they build a framework of problem-solving methods and tools from the TPM toolkit that help you understand the problems, develop process improvements, and develop a plan to implement change. They also provide an overview and introduction to the TPM methodology, detailed information on TPM implementation, and in-depth case studies. A major highlight of the book is the inclusion of case studies and applications of TPM that have shown significant improvement in meeting customer requirements and reducing downtime of processes. These in-depth descriptions demonstrate how to successfully apply TPM based on real-world projects from a wide variety of processes. They provide hands-on experience—an invaluable resource when instructing the use of methods and tools in training or in a classroom. And, these case studies give you detailed step-by-step approaches to TPM integration with clear direction from project infancy to completion.

Total Productive Maintenance


Author: Terry Wireman
Publisher: Industrial Press Inc.
ISBN: 9780831131722
Category: Business & Economics
Page: 196
View: 9992

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Completely revised and updated, this new edition of a classic reference focuses on the financial approach to the subjecta methodology that produces quantifiable results allowing a TPM program to be sustainable. And while clarifying what TPM is and what it is not, it clearly presents the economic value of TPM and shows how to calculate the Return on Investment (ROI) that a company can expect. It is the perfect resource for anyone who is considering implementing TPM or looking for ways of improving their current process.

TPM for Workshop Leaders


Author: Shirose Kunio
Publisher: Routledge
ISBN: 1351407449
Category: Business & Economics
Page: 166
View: 446

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Workshop leaders play a central role in your company's efforts to implement TPM. Once your workers have been divided into small groups to learn the fundamentals of TPM, it is the group leader who spearheads ongoing training and implementation activities. With quick-reading, people-oriented practicality, this new book addresses the role of the workshop leader in maximizing the benefits of TPM.A top TPM consultant in Japan, Kunio Shirose: Incorporates cartoons and graphics to convey the hands-on leadership issues of TPM implementationUses case studies to reinforce his ideas on training and managing equipment operators in the care of their equipmentItemizes specific activities that must be undertaken to search out, correct, and control defects to remedy equipment shortcomings.He also addresses the cooperative relationship necessary between maintenance and production and leaves you with an understanding of the three imperatives for successful TPM implementation to change the quality and functioning of the equipment, the way operators think about equipment, and the workplace. (Originally published by the Japan Management Association.)

The Kanban Playbook

A Step-by-Step Guideline for the Lean Practitioner
Author: Chris A. Ortiz
Publisher: CRC Press
ISBN: 1498741770
Category: Business & Economics
Page: 75
View: 9654

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A scheduling system for Lean and just-in-time production, Kanban is a proven tool for reducing waste, inventory, and lead times. The implementation of Kanban, however, is a manually intensive action and conducting Kanban projects properly takes experience and direction. Until now, there has been a need for a book with detailed step-by-step guidelines on how to properly implement Kanban. Complete with color images, The Kanban Playbook: A Step-by-Step Guideline for the Lean Practitioner fills this need. This new book in The LEAN Playbook Series is your guide to proper Kanban implementation. It is ideal for Lean practitioners and facilitators looking for a training tool and guideline that can be used in the work area while improvements are being made. Like a football coach, you can use this playbook for quick reference to convey what’s needed to facilitate effective Kanban projects. If for some reason you forget a "play" during the implementation, you can easily reference the playbook. You can follow page by page and use the playbook to facilitate successful Kanban projects, or you can go directly to certain topics and use it to help you implement that particular "play." The playbook includes color images from actual Kanban implementations. In addition to the images, a combination of short paragraphs and bulleted points walk you step by step through the process of implementing Kanban to reduce waste and bring about remarkable changes in your organization. Wasting little time on high-level theory, the book explains how to implement Kanban Card Systems, Two-Bin Systems, and In-Process Kanban (IPK). Looking for supplemental information or Lean coaching from Chris Ortiz? Go to www.leanplaybooks.com to receive ongoing support and advice on how to use The LEAN Playbook Series for training and implementation.

TPM implementation, a Japanese approach


Author: Masaji Tajiri,Fumio Gotō
Publisher: McGraw-Hill Companies
ISBN: N.A
Category: Business & Economics
Page: 328
View: 3791

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Reduce plant breakdowns to zero and increase productivity with this step-by-step guide to implementing TPM. Included are discussions of TPM for complete elimination of losses; the outline of TPM; the five countermeasures to TPM breakdown; and the seven steps of autonymous maintenance: initial cleaning, countermeasures to source of contamination and inaccessible area, cleaning and lubricating standards, overall inspection, autonomous inspection, process quality assurance, and autonomous maintenance in manual work. With 118 illustrations and an index.

TPM en industrias de proceso


Author: Tokutaro Suzuki
Publisher: Routledge
ISBN: 1351407503
Category: Business & Economics
Page: 404
View: 5256

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El mejor libro sobre TPM que hemos editado hasta la fecha! El enfoque TPM resulta en mejoras dramaticas en calidad, costo de producci?n y entrega de productos. En este libro, nueve autores le ensenan todos los detalles que usted necesita para implementar el TPM, y ejemplos de industrias textiles, quimicas, de alimentos, entre otras. Una de las grandes ventajas de este libro es que le ayuda a conocer la implementacion del TPM a traves de la perspectiva de consultores especializados y reconocidos.Contenido:Vision general del TPM en las industrias de proceso Maximizacion de la eficacia de la producci?n Mejora orientada Mantenimiento Autonomo Mantenimiento planificado Gestion temprana Mantenimiento de calidad Promocion de tecnicas de operacion y mantenimiento TPM en los departamentos administrativos y de apoyo Creacion de un entorno grato y seguro Actividades de pequenos grupos TPM Medicion de la eficacia del TPM

Uptime

Strategies for Excellence in Maintenance Management, Third Edition
Author: John D. Campbell,James V. Reyes-Picknell
Publisher: CRC Press
ISBN: 1482252384
Category: Business & Economics
Page: 533
View: 5542

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Uptime describes the combination of activities that deliver fewer breakdowns, improved productive capacity, lower costs, and better environmental performance. The bestselling second edition of Uptime has been used as a textbook on maintenance management in several postsecondary institutions and by many companies as the model framework for their maintenance management programs. Following in the tradition of its bestselling predecessors, Uptime: Strategies for Excellence in Maintenance Management, Third Edition explains how to deal with increasingly complex technologies, such as mobile and cloud computing, to support maintenance departments and set the stage for compliance with international standards for asset management. This updated edition reflects a far broader and deeper wealth of experience and knowledge. In addition, it restructures its previous model of excellence slightly to align what must be done more closely with how to do it. The book provides a strategy for developing and executing improvement plans that work well with the new values prevalent in today's workforce. It also explains how you can use seemingly competing improvement tools to complement and enhance each other. This edition also highlights action you can take to compensate for the gradual loss of skills in the current workforce as "baby boomers" retire.

Focused Equipment Improvement for TPM Teams


Author: JapanInstituteofPlantMaintenance
Publisher: Routledge
ISBN: 1351447734
Category: Business & Economics
Page: 142
View: 6335

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As distinguished from autonomous maintenance, where the main goal is to restore basic conditions of cleanliness, lubrication, and proper fastening to prevent accelerated deterioration, FEI looks at specific losses or design weaknesses that everyone previously thought they just had to live with. Once your TPM operator teams are progressing with their daily autonomous maintenance activities, you will want to take the next advanced step in TPM training with this book. Key Features: a simple and powerful introduction to P-M Analysis hints for unraveling breakdown analysis numerous ideas for simplifying and shortening setups ideas for eliminating minor stoppages and speed losses basic concepts of building quality into processing real-life examples from a leading Japanese tool company Educate and empower all your workers to support your TPM improvement activities with

P-M Analysis

AN ADVANCED STEP IN TPM IMPLEMENTATION
Author: Shirose Kunio,Mitsugu Kaneda,Yoshifumi Kimura
Publisher: CRC Press
ISBN: 1563273128
Category: Business & Economics
Page: 200
View: 6107

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In this large-format implementation manual, TPM experts explain P-M Analysis. (A methodology that makes zero losses a reality in your TPM program.) P-M Analysis is designed to help your TPM teams analyze and eliminate chronic problems that have been neglected or unresolved in the past. Chronic quality defects and other chronic losses are hard to eradicate, because they typically have multiple, interrelated causes that vary with every occurrence. Common improvement strategies, like cause-and-effect analysis, are usually ineffective in dealing with such complex problems. P-M Analysis was specially developed to overcome the weaknesses of traditional methods. It offers a rigorous 8-step method for ensuring that all possible factors are identified and investigated. Through P-M Analysis, teams really get in touch with their equipment. Its unique skill-building process improves technological know-how while delivering solutions to persistent problems. The first four steps of this rigorous 8-step program help teams isolate and understand the root causes of defects and failures within main equipment mechanisms and peripheral systems. The final four steps provide a systematic approach for effectively controlling those causes. A critical concept in P-M Analysis is physical analysis -- a way of thinking about how defects and failures are generated that forces us to look at the physical principles involved and to quantify the changes in the relationship between the equipment mechanisms and product parts involved. When a proper physical analysis is carried out, teams are far less likely to overlook important factors or to waste time pursuing unrelated ones. Although not a cure-all, P-M Analysis has reduced chronic losses to zero and raised technological expertise in many manufacturing environments. This illustrated implementation manual provides a thorough step-by-step procedure for implementing P-M Analysis, along with practice exercises and graded examples. It is an unparalleled resource for anyone with a basic knowledge of TPM who is ready to fine-tune their loss-reduction activities. Here, finally, is a root-cause analysis method that will help teams achieve the ultimate goal of zero losses.

Visual Controls

Applying Visual Management to the Factory
Author: Chris A. Ortiz,Murry Park
Publisher: CRC Press
ISBN: 1439820929
Category: Business & Economics
Page: 180
View: 7612

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An effective visual communication system can help manufacturing employees eliminate significant waste from daily tasks. From work-zone color coding to posted metrics, visual controls clarify and simplify the path to enhanced processes and profits. Leaving little to chance, Visual Controls: Applying Visual Management to the Factory provides a detailed explanation of how to apply the Lean principles of 5S to convert your factory to a fully functioning Visual Workplace. It covers the range of methods that collectively compose an effective visual management system and clearly explains management's role in creating a Lean strategy to accomplish the transformation. This book: Considers visual Kanban, material replenishment, and the implementation of a visual maintenance department Details management's role in implementing and sustaining a visual factory Covers the range of visual tools—including tool boards, shadow boards, metrics communication boards, and tool check cards From plant layout and department setup to visual tools and parts, this book facilitates the comprehensive understanding required to initiate positive change through visual communication. The authors supply authoritative insight on how to hasten the required cultural changes, as well as step-by-step instruction for creating visual shadow boards. They also highlight time-tested methods for measuring progress and performance with improved accuracy.

Lean Manufacturing

Tools, Techniques, and How to Use Them
Author: William M Feld
Publisher: CRC Press
ISBN: 1420025538
Category: Business & Economics
Page: 248
View: 5958

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There are some very good books available that explain the Lean Manufacturing theory and touch on implementing its techniques. However, you cannot learn "how to be" lean from merely reading the theory. And to be successful in the real-work environment you need a clear comprehension of how lean techniques work, rather than just a remote understanding of what they are. You need to know what does and does not work in different situations. And you need the benefit of practical experience in their implementation. Lean Manufacturing: Tools, Techniques, and How to Use Them gives you the benefit of author and practitioner William Feld's 15 years of hands-on experience - and the lessons he's learned. Feld provides insight into the appropriate use of assessment, analysis, design, and, most importantly, deployment of a successful lean manufacturing program. Packed with practical advice and tips but not bogged down in theory, this book covers how, why, when, and what to do while implementing lean manufacturing. It equips you with the tools and techniques you need along with an understanding of how and why they work. Feld explores why an integrated approach is so much more beneficial in securing sustained improvement. He focuses on the interdependency of the Five Primary Elements: organization, metrics, logistics, manufacturing flow, and process control. He describes a proven, applied approach to creating a lean program using these elements. To keep up globally, and even locally, your manufacturing operation must be responsive, flexible, predictable, and consistent. You must continually improve manufacturing operations and cultivate a self directed work force driven by output based, customer performance criteria. By applying what you learn from Lean Manufacturing: Tools, Techniques, and How to Use Them you can build a workforce - and an organization - with the capacity to satisfy world class expectations now and into the future.

Practical TPM

Successful Equipment Management at Agilent Technologies
Author: James Leflar
Publisher: CRC Press
ISBN: 9781563272424
Category: Business & Economics
Page: 384
View: 1346

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Agilent Technologies, formerly Hewlett-Packard's Test and Measurement Division, operates an integrated circuit fabrication plant in Fort Collins, Colorado. Guided by Masaji Taijiri, the author of 7 Steps to Autonomous Maintenance (see page 34), author Jim Leflar and his team at Agilent developed a complete TPM program for the complex equipment on their shop floor. Drawn from these experiences, Practical TPM is a must read for anyone who wants to begin successful TPM implementation. Part I explains the fundamental concepts of TPM, including the six basic principles of TPM, the goals of TPM, cultural changes resulting from TPM, and the keys to successful implementation. Part II — the heart of the book — describes, in step-by-step detail, the evolution of Agilent's TPM program. Each phase is clearly defined and demonstrated; the working tools and systems developed by the Agilent TPM team in the process are discussed at length. To conclude, Part III focuses on developing a vision and a strategy for your own successful TPM program. Replete with annotated photographs and illustrations documenting Agilent's successful program, Practical TPM: Successful Equipment Management at Agilent Technologies offers an invaluable roadmap to TPM implementation. The book covers: A step-by-step TPM program as implemented at a major US corporation The 5-why analysis method Examples of one-point lessons Using visual controls in a TPM program Tools for understanding equipment failures Improving machine productivity Improvement metrics Master checklists and forms Developing activity boards Appendices containing examples of maintenance training materials For a PDF file with the preface and table of contents click here. For a PDF file with the first chapter click here.

Implementing TPM

The North American Experience
Author: Charles J. Robinson,Andrew Ginder
Publisher: Productivity Press
ISBN: 9781563270871
Category: Business & Economics
Page: 197
View: 3752

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Learn from these authors' experiences tailoring TPM to the distinctive needs of North American plants, and how TPM fits into an overall manufacturing improvement strategy. A real-world view on what works and what doesn't. Robinson and Ginder provide an excellent resource for strategic planning and an educational tool for middle and upper management. Includes the seven levels of autonomous maintenance, a discussion of unions and TPM, and a TPM master plan.