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Total Productive Maintenance Proven Strategies and Techniques to Keep Equipment Running at Maximum Efficiency

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ISBN-10: 0071467335

ISBN-13: 9780071467339

Edition: 2006

Authors: Steve Borris

List price: $125.00
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Description:

With equipment downtime costing companies thousands of dollars per hour, many turn to Total Productive Maintenance as a solution. Short on theory 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.
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Book details

List price: $125.00
Copyright year: 2006
Publisher: McGraw-Hill Education
Publication date: 1/21/2006
Binding: Hardcover
Pages: 448
Size: 6.40" wide x 9.20" long x 1.10" tall
Weight: 1.584
Language: English

Steven Borris has 33 years of maintenance and training experience -- 20 years working for US companies. While a Senior Engineer at Varian's European Implanter group, he oversaw all operating issues, supported customers, advised on improvement initiatives and provided training for operation/maintenance and electronics.

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