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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.
"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."--Provided by publisher.
Implementing TPM by Andrew Ginder,Alan Robinson,Charles J. Robinson Pdf
This book provides an understanding of the complexity and comprehensiveness of the total productive maintenance (TPM) process. It supplements works by Japanese authors with guidance and detail on how the TPM process relates to North American plants or facilities.
Autonomous Maintenance in Seven Steps by Fumio Gotoh Pdf
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.
TPM: Collected Practices and Cases by Productivity Press Pdf
Equipment downtime can bring a lean manufacturing operation to a complete standstill. Total productive maintenance (TPM) is such a fundamental part of becoming lean because a machine failure at one step of a continuous flow process will halt all the steps before and after it. Strategies aimed at eliminating downtime are essential in any operation i
Lean for the Process Industries by Peter L. King Pdf
Compared to its widespread implementation across almost all areas of production, Lean improvement efforts lag within the process industries. While many innovators have successfully applied Lean principles to these industries during the past three decades, most of those pioneering efforts were never recorded to guide the improvement efforts of others. Drawing on more than 40 years of application experience at one of the world’s largest chemical and materials manufacturers, coupled with 10 years in private practice, Peter King corrects this void by providing the first comprehensive resource written explicitly for change agents within the process industries. Focusing on areas where the improvement needs of the process industry differ from parts assembly manufacturing, Lean for the Process Industries: Dealing with Complexity, Second Edition: Covers each of the eight wastes commonly described in Lean literature, looking at how they manifest themselves in process operations. Explains how to adapt value stream mapping for process operations. Shows how to identify the root causes of bottlenecks, and how to manage them to optimize flow until they can be eliminated. Provides practical techniques to overcome the barriers which have prevented the application of Cellular Manufacturing to process operations. Discusses the role of business leadership in a Lean strategy, describing both enabling and counter-productive management behaviors Since the publication of the first edition of this book, Peter King has been busy consulting with food, beverage, gasoline additive, and nutraceutical companies -- these new experiences have broadened his perspectives on certain Lean processes and have given him a richer set of examples to discuss in this new edition. While Value Stream Mapping is a very powerful tool to understand flow, bottlenecks, and waste in an operation, the traditional format as presented in many other books does not describe all of the data required to fully understand process flow and its detractors. This new edition highlights the necessary additions with examples of why they are useful. Product wheel scheduling achieves production leveling in a far more comprehensive and effective way than traditional heijunka methods. This edition has a more thorough description of the wheel concept and design steps, and more examples from actual applications.
P-M Analysis by Shirose Kunio,Mitsugu Kaneda,Yoshifumi Kimura Pdf
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 era
Total Productive Maintenance by Tina Kanti Agustiady,Elizabeth A. Cudney Pdf
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
Equipment Management in the Post-Maintenance Era by Kern Peng Pdf
Recent advancements in information systems and computer technology have led to developments in equipment and robotic technology that have permanently changed the characteristics of manufacturing equipment. Equipment Management in the Post-Maintenance Era: A New Alternative to Total Productive Maintenance (TPM) introduces a new way of thinking to help high-tech organizations manage an increasingly complex equipment base. It also facilitates the fundamental understanding of equipment management those in traditional industries will need to prepare for the emerging microchip era in equipment. Kern Peng shares insights gained through decades of managing equipment performance. Using a systems model to analyze equipment management, he introduces alternatives in equipment management that are currently gaining momentum in high-tech industries. The book highlights the fundamental internal flaw in maintenance organizational setup, presents new approaches to replace maintenance functional setup, and illustrates a time-tested transformation and implementation process to help transition your organization from the maintenance era to the new post-maintenance era. Breaks down the history of equipment into five phases Provides a clear understanding of equipment management fundamentals Introduces alternatives in equipment management beyond the mainstream principles of maintenance management The book examines maintenance management logistics, including planning and budgeting, training and people development, customer services and management, vendor management, and inventory management. Supplying a comprehensive look at the history of equipment management, it analyzes current maintenance practice and details approaches that can significantly improve the effectiveness and efficiency of your equipment management well into the future.
Production Scheduling for the Process Industries by Peter L. King,Mac Jacob,Noel Peberdy Pdf
This book is aimed at manufacturing and planning managers who struggle to bring a greater degree of stability and more effective use of assets to their operations, not realizing the degree to which production scheduling affects those objectives. It has been reported that 75% of the problems on the manufacturing floor are caused by activities outside the plant floor. Poor production scheduling strategies and systems are often the biggest contributors to the 75%. The book explains in detail that no scheduling strategy, and especially no transition to a different and better scheduling strategy, will succeed without strong commitment and guidance from senior leadership. Leadership must understand their active role in the transition, that people will feel uncomfortable and even threatened by change, and that they will need to be measured by different standards. Effective scheduling requires that following the schedule and production to plan is more important than trying to maximize each day’s throughput. The book explains the advantages of a structured, regularly repeating schedule: how it can increase throughput, right-size inventory based on cycles and variabilities and therefore make it more usable, and improve customer delivery. It will explain the trade-offs between throughput, inventory, and delivery performance, how those trade-offs are actually decided in production scheduling, and how an appropriate scheduling strategy can make the trade-offs and their ramifications visible. It discusses several popular structured scheduling concepts, their similarities, and differences, to allow the readers to decide which might fit best in their environments. In addition, the authors discuss what makes an appropriate scheduling software system, and why a package designed for structured scheduling offers capabilities well beyond the Excel workbooks used by many companies, and how it offers much more design capability and ease of use than the finite scheduling modules in SAP or Oracle. Finally, the authors offer a proven roadmap for implementation, critical success factors necessary to achieve the full potential, and give examples of operations that have done this well. In addition, a guide for leaders and managers post-implementation is provided to help them fully exploit the advantages of a structured, repeating scheduling strategy.
While Lean practices have been successfully implemented into the process industry with excellent results for over 20 years (including the author‘s own award winning example at Exxon Chemical), that industry has been especially slow in adopting Lean. Part of the problem is that the process industry needs its own version of Lean. The larger part of t
A companywide approach to improving the effectiveness and longevity of equipment and machines, Total Productive Maintenance (TPM) is a critical component of production line success. The need for a step-by-step guidelines on how to achieve TPM has been filled with the publication of The TPM Playbook: A Step-by-Step Guideline for the Lean Practitione
Kanban Just-in Time at Toyota by Japan Management Association Pdf
Toyota's world-renowned success proves that just-in-time (JIT) makes other manufacturing practices obsolete. This simple but powerful book is based on the seminars given by Taiichi Ohno and other senior production staff to introduce Toyota's own supplier companies to JIT. It teaches the philosophy and implementation of what many call the most efficient production system in the world. Provides a clear structure for an introductory JIT training program. Explains every aspect of the JIT system, including how to set it up and how to refine it once it's in place. Shows how to use a simple visual system to control the production process. Every day more American companies are learning that JIT works outside Japan. Now you can get started with this step-by-step book which guides you through the implementation process. Every engineer, manager, supervisor, and worker should read this book to get the clearest, simplest, and most complete introduction to JIT available in English. Results at American companies after reading this book: Lead-time on one product was reduced from 12 weeks to 4 days. Setup time on a large blanking press was reduced from eight hours to one minute and four seconds. Work-in-process has been reduced 50 percent plant-wide. Factory floor space was opened up 30 to 40 percent in every on of their plants.
LEAN MANAGEMENT: THE LAUNCHPAD FOR GLOBALIZATION, INDUSTRIAL REVOLUTION AND IMPOWERMENT by Dr. Suresh Sharma Pdf
Lean Manufacturing concept has brought new industrial revolution and the battle lines are clearly drawn. It is traditional mass production versus the trim and tidy lean Enterprising. Lean experts and past researchers plead; Lean production is a superior way for humans to make things. It provides better products in wider variety at lower cost. It provides more challenging and fulfilling work for employees at every level. The whole world should adopt lean production, and as quickly as possible. Henry Ford defined Lean Enterprising stating, “If it does not add value, it is waste”. This concept was later adopted by Toyota as the core idea behind the famous Toyota Production System (T.P.S). The Toyota Production System is the foundation of many books on “lean”. It is the story of Lean Production how Japan’s secret weapons in the global auto wars later revolutionized western industries. The concept of lean manufacturing was widely accepted. A Standard S.A.E J 4000:1999 was also released to specify Lean in detail. The purpose of this book is to share the knowledge and experience gained through collaborative contribution - with a wide range of readers including; students, managers, entrepreneurs, industrial leaders, university professors, and self-learning professionals. Implementation of lean practices mainly in automobile and engineering industries provide valuable insight. Further, the book describes how it can be applied to wider field of work including; shipbuilding, information technology, environmental protection, transportation services and performance management from human resource perspective. My presentations on LEAN in conferences and published papers in international journals like; Elsevier, IEEE, and David Publishing-USA are also included to provide valuable inputs. This book recommends the solution for immediate problems faced by industries and service sectors using lean principles and practices. The generic but common and critical problems that are discussed in depth include; economic crisis, global competition, scarce resources, quality issues, waste generation, volatile market, global warming, and poor performance. These issues have also been examined by the author in his other book, “Management Paradox: Re-examined” as source of tension, dilemma and contradiction. Relevant tools and techniques that are addressed and applied include; Kaizen, Five ‘S’, Visual Management, Just in Time, Kanban System, One Piece Flow, Single Minute Exchange of Die, Total Productive Maintenance and Poka Yoke. For a specific reason mistake-proofing (Poka Yoke) has been elaborated in detail for exploring its effectiveness to add value in product and services. This powerful lean tool took a long time to acquire its place in the list of popular tools because it challenged the effectiveness of statistical process control towards achieving zero-defect. The quantitative and qualitative approaches that have been selected and used based on the field of work and situation will be found interesting by research scholars. Methods like correlation analysis, test of hypothesis, and analysis of variance (ANOVA) have been carried out using the quantitative technique. Qualitative approach has been used for lean and sustainable transport system to understand people’s belief, perspective and experience. This approach supported in handling the important issues of consent and confidentiality. The book also presents the arguments on potential limitations of the lean manufacturing strategy on one hand and criticism on drifting definition of lean on other hand. The book firmly suggests instant applicability of lean principles and practices in sectors like manufacturing and construction. The way to apply lean in other sectors including ICT in conjunction with present practices like; agile for knowledge to apply tools, scrum for experience-based self-direction etc. are recommended. These sector- specific practices are supported by lean principles but the book discovers that exclusively focusing on software development without considering upstream and downstream operations severely limit the benefits. Therefore lean principles support agile and scrum and take much beyond software development. The ideas and recommendations offered in this book can be used for further implementation of lean in a large number of organizations and different fields including MSME, service-providing industries, healthcare, construction management, management education, and for army reforms. A leaner, modern military is the need of the hour.
