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List of Figures, Formulas, and Tables | |
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Preface | |
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Acknowledgments | |
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Introduction | |
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The Development of Maintenance Systems | |
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The Writing Technique and the Contents of the Book | |
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The Pillars of TFM | |
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The Toyota Production System (Also Known As Lean Manufacturing) | |
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Finally, Advice for Using the Techniques | |
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TPM-Basic, Use, and Ideal Conditions | |
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Fault Development | |
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The Basic Condition | |
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Technical Standards | |
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Overall Equipment Efficiency | |
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The availability of the equipment | |
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The performance of the equipment | |
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The quality of the product | |
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Natural and Forced Deterioration | |
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Use Conditions | |
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The Ideal Condition | |
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Improvement Methodology | |
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How Do We Restore the Basic Condition? | |
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TPM Jishu-Hozen-Autonomous Maintenance | |
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The TPM Initial Clean and Inspect and F-Tagging | |
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The Cleaning Map: What and Where to Clean | |
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F-Tags: How to Record Fuguai | |
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Discovery of a Serious Fault during the Cleaning | |
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Tracking the Progress of the Initial Cleans | |
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TPM-Analyzing and Categorizing the Failure Data | |
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F-Tags, The Machine History Log, and Minor Stops or Unrecorded Losses Categorizing | |
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Finding Out the TPM Causes for the F-Tags to Hlep Find the Cure | |
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Pareto Charts | |
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The Defect Map | |
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TPM-Creating Standards and Preparation for Autonomous Maintenance | |
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Task Transfer: Red to White F-Tags or PM to AM Tasks | |
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Explanation of the Embedding and Responsibility Spreadsheet | |
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PM Teams (Kobetsu Kaizen) | |
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TPM: The Education & Training and Safety Pillars | |
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The TPM Education & Training Pillar | |
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Equipment training | |
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A sequence for training equipment | |
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Competency: How does TPM assess the skill level of the team members? | |
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The TPM Safety Pillar | |
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The area map | |
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The hazard map | |
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Risk assessment | |
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Safe working procedures: Using as standards | |
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5S: Organization and Improvements by Default | |
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5S: SSSSS-The Meaning | |
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The Benefits of 5S | |
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The Decision to Implement 5S | |
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Initial Management Implementation | |
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Audit sheets | |
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The red tag holding area | |
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Seiri-Sort | |
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Red tag details | |
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Seiton-Set in Order | |
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Seiso-Shine | |
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The 5S cleaning map or assignment map | |
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Seiketsu-Standardization | |
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Shitsuke-Self-Discipline | |
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SMED-Single Minute Exchange of Die | |
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Where Did SMED Originate? | |
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Creating the SMED Team | |
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The team members and their responsibilities | |
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Select the Tool | |
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Document Every Step of the Changeover | |
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Viewing the Changeover as a Bar Graph | |
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Define the Target Time for the Changeover | |
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Analysis of the Elements | |
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The SMED Analysis | |
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Implementing ideas | |
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Create the new procedure | |
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Repeating the Exercise | |
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Applying SMED to Maintenance and the Use of Turnaround Parts | |
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Deciding on a Maintenance Strategy | |
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The TPM PM Analysis | |
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The malfunction and PM maps | |
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Interpreting PM maps | |
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Scheduled maintenance or scheduled restoration | |
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Scheduled replacement or scheduled discard | |
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The RCM PM Analysis | |
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The RCM decision diagram | |
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Failure is unacceptable: Redesign the system | |
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Recording the process on the decision worksheet | |
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Failure finding and calculating acceptable risk | |
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RCM-Reliability Centered Maintenance | |
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The First Stage in an RCM Analysis: The Operating Context | |
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Example of a Furnace Boatloader Operating Context: Tool Analysis Level | |
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Equipment Defined as Functions | |
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Identifying Functions and Labeling | |
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Functional Failures to Failure Effects | |
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Failure modes | |
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Failure effects | |
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Where Did RCM Come From? | |
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Non-Time-Based Failures | |
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Infant mortality | |
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Time- and Condition-Based Maintenance | |
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Introduction to On-Condition Maintenance | |
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Friction between Maintenance and Production | |
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What if we were starting from scratch? | |
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In Summary | |
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Fault Analysis: A Few Ways to Help Find Root Causes | |
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The 5 Why's | |
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Fishbone Diagrams | |
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Fault Tree Diagrams | |
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OCAPs: Out-of-Control Action Plans | |
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Team Objectives and Activity Boards | |
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Activity Boards | |
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Team Goals | |
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Monitoring Progress | |
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What do we monitor? | |
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How do we calculate the failure rate and the target improvement? | |
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Authority for Working in Specific Machine Areas | |
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What Do the Results of a Real RCM Analysis Look Like? | |
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Summary of the boatloader analysis | |
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Lean Manufacturing | |
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Defects | |
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Overproduction | |
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Waiting | |
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Transporting | |
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Overprocessing | |
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Unnecessary inventory | |
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Unnecessary operator movement | |
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Value | |
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Equipment | |
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Pull | |
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Six Sigma: A High-Level Appreciation | |
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Graphs and Their Use in Six Sigma | |
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Average and standard deviation | |
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Standard deviation and z scores | |
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The x-y graph | |
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The Main Terms of Six Sigma | |
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The customer | |
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The teams and the leaders | |
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The Champion or Sponsor | |
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Six Sigma Controller | |
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The Rules and Expectations | |
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The Six Sigma Charter | |
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The Technical Stuff | |
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The sigma value | |
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Defects per opportunity | |
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Defects per million opportunities | |
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The Stages of a Six Sigma Analysis | |
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Considerations or Limitations in Using Six Sigma | |
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Faultfinding the cause of a lamp failure | |
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Possible Limitations with Using Statistics | |
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Index | |