Total Productive Maintenance – Strategies and Implementation Guide – Second Edition

Total Productive Maintenance – Strategies and Implementation Guide – Second Edition
اسم المؤلف
Tina Agustiady and Elizabeth A. Cudney
التاريخ
23 فبراير 2024
المشاهدات
153
التقييم
(لا توجد تقييمات)
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Total Productive Maintenance – Strategies and Implementation Guide
Second Edition
Tina Agustiady and Elizabeth A. Cudney
Contents
About the Authors xv
Chapter 1 Instructional Strategies .1
1.1 Purpose 1
1.2 TPM Project Backgrounds 1
1.3 TPM Case Study Goals .1
1.4 Learning Design 2
Chapter 2 Introduction 3
2.1 TPM .3
2.2 Four-Phase Approach 4
2.3 Conclusion .6
References 7
Chapter 3 Overview of TPM .8
3.1 TPM .8
3.2 History of TPM .8
3.3 Goals and Benefits of TPM .9
3.4 TPM Stages .9
3.4.1 Stage 1: Preparation . 10
3.4.2 Stage 2: Introduction 10
3.4.3 Stage 3: Implementation 10
3.4.4 Stage 4: Institutionalize . 10
3.5 Pillars of TPM . 11
3.5.1 Pillar 1: 5S 11
3.5.2 Pillar 2: Autonomous Maintenance . 11
3.5.3 Pillar 3: Kobetsu Kaizen 12
3.5.4 Pillar 4: Planned Maintenance . 13
3.5.5 Pillar 5: Quality Maintenance 13
3.5.6 Pillar 6: Training 14
3.5.7 Pillar 7: Office TPM 14
3.5.8 Pillar 8: Safety, Health, and Environment . 14
3.6 Conclusion .15
References 15
Chapter 4 TPM and Six Sigma . 16
4.1 Six Sigma . 16
4.2 Variation 17 viii Contents
4.3 Project Charter 19
4.4 Supplier-Input-Process-Output-Customer Diagram 20
4.5 Kano Model . 21
4.6 Critical-to-Quality Characteristics 22
4.7 Affinity Diagram .22
4.8 Measurement Systems Analysis 23
4.9 Process Capability .27
4.9.1 Capable Process .27
4.9.2 Capability Index .28
4.9.3 Process Capability Index Applications 29
4.9.4 Potential Abuse of C
p and Cpk 29
4.10 Graphical Analysis 32
4.11 Cause and Effect Diagram .32
4.12 Failure Modes and Effects Analysis 34
4.13 Hypothesis Testing 36
4.14 Analysis of Variance .37
4.15 Correlation .38
4.16 Simple Linear Regression 38
4.17 Theory of Constraints 42
4.18 Single-Minute Exchange of Dies .43
4.18.1 Stage 1: Separate Internal versus External Setup 45
4.18.2 Stage 2: Convert Internal Setups to External
Setups .46
4.18.3 Stage 3: Streamline the Setup Operation .47
4.19 Conclusions 48
Reference 49
Chapter 5 Empowering and Encouraging Associates to Use TPM 50
5.1 The People Side of TPM 50
5.1.1 Just-in-Time Pillar 52
5.1.2 Respect for People Pillar 52
5.2 Conclusions 57
Chapter 6 Types of Maintenance 58
6.1 Maintenance 58
6.2 Breakdown Maintenance .58
6.3 Preventive Maintenance 59
6.3.1 Periodic Maintenance 60
6.3.2 Predictive Maintenance .62
6.4 Corrective Maintenance 63
6.5 Maintenance Prevention 65
6.6 Conclusion .67
References 68 Contents ix
Chapter 7 Overall Equipment Effectiveness .69
7.1 Overall Equipment Effectiveness 69
7.2 Planned versus Total Maintenance 73
7.3 Maintainability 73
7.4 Reliability 74
7.5 Equipment FMEA . 75
7.6 Conclusion .77
References 78
Chapter 8 Introducing and Institutionalizing TPM 79
8.1 Introducing TPM .79
8.2 Deploying TPM .80
8.3 Institutionalizing TPM 80
8.3.1 TPM Purpose .80
8.3.2 Equipment Maintenance 82
8.3.3 Operator Involvement 83
8.4 Implementing TPM .85
8.5 Conclusion .86
References 87
Chapter 9 Preparatory and Introduction Stages 88
9.1 Preparatory Stage 88
9.2 Conclusion .95
References 97
Chapter 10 Organizational Change Management .98
10.1 Change Management and Organizational Culture 98
10.2 Resistance to the Status Quo . 103
10.3 Utilizing Known Leaders to Challenge the Status Quo 103
10.4 Communicating Change 104
10.5 Conclusion .106
References 107
Chapter 11 Incorporating TPM into the Strategic Goals of the
Organization . 108
11.1 Strategic Lean Implementation . 108
11.2 Two Levels of Policy Deployment . 110
11.3 Planning for Policy Deployment . 110
11.4 Daily Management of Policy Deployment 111
11.5 Develop a Hoshin Strategic Plan Summary 114
11.5.1 How to Create a Hoshin Strategic Plan
Summary for the Organization 114 x Contents
11.6 Drive the Strategy Down to the Department
Level—Develop a Hoshin Plan Summary 116
11.6.1 Develop Implementation Strategies for the
Hoshin Plan Summary . 117
11.6.2 Decide Where to Focus the Improvement
Efforts 117
11.7 Develop the Hoshin Action Plan . 118
11.8 Develop the Hoshin Implementation Plan .120
11.9 Conduct a Hoshin Implementation Review . 121
11.10 The Three Main Tools of Policy Deployment .122
11.10.1 Deming’s Plan-Do-Check-Act Cycle 123
11.10.2 Cross-Functional Management .123
11.10.3 Catchball .124
11.11 Conclusion .124
Reference 126
Chapter 12 TPM Tools and Best Practices .127
12.1 Autonomous Maintenance .127
12.1.1 Specialized Maintenance . 138
12.1.2 Equipment Kaizen . 139
12.1.3 Early Equipment Management 140
12.1.4 Organizations and Prioritization 140
12.2 Conclusions 142
Chapter 13 TPM and Life Cycle Cost . 143
13.1 TPM . 143
13.2 Conclusion .150
Chapter 14 TPM Case Study: First Pass Quality 152
14.1 Executive Summary 152
14.2 Introduction . 153
14.3 Define 153
14.4 Measure . 155
14.5 Analyze 159
14.6 Improve 163
14.7 Control . 172
14.8 Conclusion . 173
Chapter 15 TPM Case Study: Hydraulic Leak Reduction 174
Chad Olson, Xueyang Chen, Heng Liu, and
Elizabeth A. Cudney
15.1 Introduction . 174 Contents xi
15.2 Define 175
15.3 Measure . 175
15.4 Analyze 177
15.5 Design 179
15.6 Verify . 180
15.7 Improve 181
15.8 Control . 182
15.9 Conclusions 183
References 183
Chapter 16 TPM Case Study: Pressure Regulator 184
Bill Dean, Charlie Barclay, Nanda Dey, and
Elizabeth A. Cudney
16.1 Executive Summary 184
16.2 Define 184
16.2.1 Problem Statement . 184
16.2.2 Problem Goals 185
16.2.3 Requirements and Expectations . 186
16.2.4 Project Boundaries . 186
16.2.5 Process Flow Diagram . 186
16.3 Measure . 187
16.4 Gage Repeatability and Reproducibility . 187
16.4.1 Data Collection 187
16.4.2 Process Baseline 187
16.4.3 Graphical Analysis . 191
16.5 Analyze 193
16.5.1 Failure Modes and Effects Analysis 193
16.5.2 Sources of Variation . 196
16.5.3 Prioritization of Improvement Opportunities 196
16.5.4 Hypothesis Testing . 196
16.6 Improve 197
16.7 Control .200
16.8 Conclusions 200
References 200
Chapter 17 TPM Case Study: Roller Assembly Redesign 201
DeVaughan Woodside, Apurva Chinchore, Sujitkumar
Dongare, and Elizabeth A. Cudney
17.1 Introduction . 201
17.2 Project Description 201
17.3 Project Goals .204
17.4 Requirements and Expectations 204
17.5 Project Boundaries 205
17.6 Project Management 205 xii Contents
17.7 Gantt Chart 205
17.8 Invent/Innovate 209
17.8.1 SWOT Analysis (VOC) .209
17.9 Critical to Satisfaction . 211
17.10 Data Collection Plan 212
17.11 Quality Function Deployment . 213
17.12 Design 214
17.13 Concept Generation (3P) . 214
17.14 Seven Concepts 215
17.15 Pugh’s Concept Selection 220
17.16 Prototype Selected/Final Design . 221
17.17 Optimize 221
17.17.1 Design Failure Modes and Effects Analysis 221
17.18 Validate 224
17.18.1 Process at a Glance 224
17.19 Trial Runs 226
17.20 Financial Savings .227
17.21 Conclusion .228
References 228
Chapter 18 TPM Case Study: Sticky Foil .229
Adebolaji Jobi‑Taiwo, Adam Miller, Amelia Lopez, and
Elizabeth A. Cudney
18.1 Introduction .229
18.2 Project Charter and Project Management Plan Highlights .229
18.2.1 Project Charter .229
18.3 Project Management Plan 230
18.4 Define 230
18.5 Problem Statement .230
18.6 Problem Goals .232
18.7 Requirements and Expectations 232
18.8 Project Boundaries 233
18.9 Process Flow Diagram 233
18.10 Measure .233
18.11 Data Collection 233
18.12 Process Baseline 237
18.13 Process Data 237
18.14 Analyze 242
18.15 Current Performance and Customer Expectations 242
18.16 Sources of Variation 243
18.17 Gap Analysis .245
18.18 Improve 245
18.19 Possible Causes Ruled Out 245
18.20 Potential Causes to Analyze Further .246
18.21 Control .246 Contents xiii
18.22 Financial Savings .246
18.23 Conclusions 248
Chapter 19 Future and Challenges of TPM 249
19.1 TPM in Service and Healthcare 249
19.1.1 Applying TPM Concepts to the Design and
Development Life Cycle .249
19.2 Engagement and Success Factors 251
References 253
Index 255 xv
Index
A
affinity diagram, 22
analyze, 16
ANOVA, 37
autonomous maintenance, 10, 11, 12,
79, 83, 127
B
benefits, 9
bias, 24
breakdown maintenance, 58
capability index, 24
catchball, 124
cause and effect diagram, 18
central tendency, 18
changeover, 43
common cause variation, 18
communicating change, 104
continuous improvement, 16
control, 16
corrective maintenance, 63
correlation, 38
cost, 51
critical to quality, 22
cross functional management, 122
D
define, 16
delivery, 44
Deming, 18, 123
deploying TPM, 80
description, 19
design and development, 249
discrimination, 23–24
DMAIC, 16
DPMO, 17
E
early equipment management, 140
empowering, 50
encouraging, 50
engagement and success factors, 251
environment, 14
equipment FMEA, 75
Equipment Kaizen, 139
equipment maintenance, 80
F
failure modes and effects analysis, 34
Five S, 13
focus five pillars, 143
four-phase approach, 4, 5
future and challenges of TPM, 249
G
gage R&R, 25
goals, 8, 9
graphical analysis, 32
H
health, 14
history, 8
hoshin planning, 111, 113
hypothesis testing, 36
I
implementation, 5, 9, 79
improve, 16
innovative approach, 3
institutionalization, 9, 86
instructional strategies, 1
introduction, 9
J
Japanese Institute of Plant Engineers, 8
jidoka, 52
just in time, 52, 99
K
Kano, 18
Kobetsu Kaizen, 12
L
lean business system, 53
learning design, 2
life cycle cost, 143
location, 18
losses, 3 256 Index
M
maintainability, 73
maintenance prevention, 65
maintenance, 58
measure, 16
measurement capability index, 24
measurement systems analysis, 23
O
objectives, 4
office TPM, 14
operator involvement, 83–84
organizational change management, 98
overview, 8
overall equipment maintenance, 71
P
periodic maintenance, 60
PERT, 56
physical quality analysis, 6
pillars, 11
Plan Do Check Act, 111
planned maintenance, 13, 73
policy deployment, 110
predictive maintenance, 62
preparation, 10, 88
preventive maintenance, 59
process capability, 27
project charter, 19
P/T, 24
Q
quality, 50, 51
quality maintenance, 13
R
rapid response team, 129
reliability, 74
repeatability, 23, 24
reproducibility, 23, 24
residuals, 41
resistance, 103
respect, 52
risk priority number, 76
S
safety, 14
scope, 51
simple linear regression, 38
single minute exchange of dies, 43
SIPOC, 20
Six Sigma, 16
special cause variation, 16
specialized maintenance, 138
spread, 16
stages, 9
status quo, 98
strategic lean implementation, 108
streamline, 47
T
theory of constraints, 42
time, 51
total productive maintenance, 3, 8, 52, 74
total variation, 24
training, 5, 14
V
variation, 17
W
waste, 53, 54

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