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