TPM implementation: a Japanese approach
Gespeichert in:
| Hauptverfasser: | , |
|---|---|
| Format: | Buch |
| Sprache: | English Japanese |
| Veröffentlicht: |
New York u.a.
McGraw-Hill
1992
|
| Schriftenreihe: | Industrial and plant engineering
|
| Schlagworte: | |
| Online-Zugang: | Inhaltsverzeichnis |
| Beschreibung: | XX, 328 S. Ill., graph. Darst. |
| ISBN: | 0070628343 |
Internformat
MARC
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| 100 | 1 | |a Tajiri, Masaji |e Verfasser |4 aut | |
| 240 | 1 | 0 | |a TPM suishin no pointo, jishu hozen nanatsu no suteppu |
| 245 | 1 | 0 | |a TPM implementation |b a Japanese approach |c Masaji Tajiri ; Fumio Gotoh |
| 264 | 1 | |a New York u.a. |b McGraw-Hill |c 1992 | |
| 300 | |a XX, 328 S. |b Ill., graph. Darst. | ||
| 336 | |b txt |2 rdacontent | ||
| 337 | |b n |2 rdamedia | ||
| 338 | |b nc |2 rdacarrier | ||
| 490 | 0 | |a Industrial and plant engineering | |
| 650 | 4 | |a Plant maintenance |z Japan | |
| 650 | 4 | |a Total productive maintenance | |
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Datensatz im Suchindex
| _version_ | 1804124209590304769 |
|---|---|
| adam_text | Contents
Preface xiii
Introduction xv
Chapter 1. TPM Aims at the Elimination of Losses 1
11 The Shopfloor Suffers from Diverse Mistakes 1
1 2 The Shopfloor Is Flooded with Losses 2
1.3 Understanding the Nature of Losses 3
1.3.1 Six big losses 3
1.3.2 Chronic losses and sporadic losses 6
1.4 Why Losses Occur 7
1.4.1 Causes of losses 7
1.4.2 Equipment defects grow 8
1.4.3 Forced deterioration and natural deterioration 10
1.4.4 Hidden defects and exposed defects 12
Chapter 2. A Summary of TPM 15
2.1 Six Major TPM Activities 15
2.1.1 The elimination of six big losses 16
2.1.2 Planned maintenance 17
2.1.3 Autonomous maintenance 20
2.1.4 Preventive engineering 20
2.1.5 Easy to manufacture product design 21
2.1.6 Education 21
2.2 The Effects and an Evaluation of TPM 21
2.3 The TPM Master Plan 22
2.4 The TPM Steering Organization 23
2.4.1 An overlapped small group organization 23
2.4.2 The committee and the project team 25
2.4.3 The TPM office 25
Chapter 3. The Five Countermeasures to Achieve Zero Breakdowns 29
3.1 The Basic Strategy to Attain Zero Breakdowns 29
3.1.1 Establish basic equipment conditions 30
3.1.2 Adhere to the usage conditions of equipment 34
vii
viii Contents
3.1.3 Restore deteriorated parts 34
3.1.4 Correct design weaknesses 36
3.1.5 Enhance operating and maintenance skills 37
3.2 Who Takes the Five Countermeasures? 40
3.3 Restructuring the Roles of the Production and Maintenance
Departments 41
3.4 Allocating Roles to the Production and Maintenance Departments 43
3.4.1 Maintenance activities for the production department
(autonomous maintenance) 44
3.4.2 Maintenance activities for the maintenance department
(full time maintenance) 46
Chapter 4. The Autonomous Maintenance Program 51
4.1 The Aims of Autonomous Maintenance 51
4.1.1 Reconsidering the operator s role 51
4.1.2 The knowledgeable operator 53
4.1.3 Training operators toward a new type of engineering status 54
4.1.4 The orderly shopfloor 55
4.2 The Autonomous Maintenance Development Program 57
4.2.1 The seven steps of autonomous maintenance 57
4.2.2 The first stage of the development program (Steps 1, 2, and 3) 57
4.2.3 The second stage of the development program (Steps 4 and 5) 63
4.2.4 The third stage of the development program (Step 6) 65
4.2.5 The completion stage of the development program (Step 7) 66
4.3 The Step by Step Development of Autonomous Maintenance 66
4.3.1 The CAPD cycle 66
4.3.2 Managers must take the lead and demonstrate by example 67
4.3.3 The autonomous maintenance audit 69
4.4 Work Procedures and Standards 72
4.4.1 Why are the rules not followed? 72
4.4.2 Operators set the rules 73
4.5 Educational Systems in Autonomous Maintenance 74
4.5.1 Types of education 74
4.5.2 Means of education 76
4.6 Notes for Successful TPM Implementation 77
4.6.1 Autonomous maintenance is the job 77
4.6.2 The short remedial program 77
4.6.3 The PM group prepares action plans 77
4.6.4 Allocating equipment by PM groups 79
4.6.5 Encouraging autonomous maintenance activities 79
4.6.6 Preventing dropout from TPM activities 82
4.7 The Twelve Keypoints of Autonomous Maintenance 84
Chapter 5. Step 1: Initial Cleaning 85
5.1 Aims from the Equipment Perspective 85
5.1.1 Initial cleaning 85
5.1.2 Cleaning is inspection 86
5.2 Aims from the Human Perspective 87
5.2.1 Establish familiarity with small group activities by way of
easy tasks 88
5.2.2 Enhance operators motivation to take care of equipment 89
Contents ix
5.3 How to Develop Step 1 89
5.3.1 The activity board and the four lists 89
5.3.2 The education accomplished by answering operators
questions is effective 99
5.3.3 Develop countermeasures to misoperations from early on 99
5.4 How to Proceed with Initial Cleaning 100
5.4.1 How to divide a step into substeps 100
5.4.2 Safety education 101
5.4.3 Arrange for cleaning utensils and hand tools 103
5.4.4 How to proceed with cleaning 103
5.4.5 Thoroughly remove unnecessary components from equipment 104
5.5 Case Study 105
5.5.1 Typical activities during initial cleaning 105
5.5.2 Severe defects detected during initial cleaning 105
5.5.3 The challenge to achieve Zero foreign particles in the
semiconductor industry 107
5.6 The Keypoints of an Autonomous Maintenance Audit 107
Chapter 6. Step 2: Countermeasures to Sources of Contamination 113
6.1 Aims from the Equipment Perspective 113
6.2 Aims from the Human Perspective 113
6.2.1 Learn how to solve problems and experience satisfaction with
successful outcomes 113
6.2.2 Learn about the working mechanisms of machinery 114
6.3 Time Targets for Cleaning and Tentative Standards 115
6.3.1 Time targets for cleaning 115
6.3.2 Prepare tentative cleaning standards and work toward
improvement 116
6.4 How to Develop Step 2 116
6.4.1 Substeps and the priority of countermeasures 116
6.4.2 Types of sources of contamination 117
6.4.3 Countermeasures to difficult cleaning areas 119
6.4.4 Preexamination and postevaluation of countermeasures 120
6.4.5 Where where analysis and why why analysis 121
6.4.6 Use corrugated paper and transparent plastic board to prevent
dispersion 123
6.4.7 Keep records of equipment modifications 123
6.4.8 Review unresolved issues 123
6.5 Case Study 124
6.5.1 Preventing chips from scattering: the coverless cover 124
6.5.2 Countermeasure to drilling chips 126
6.5.3 Eliminating foreign particles in semiconductor manufacturing
vacuum processes 130
6.5.4 Measures for containing emery powder 130
6.5.5 Cleaning difficulties at a dipping basin 135
6.6 The Keypoints of an Autonomous Maintenance Audit 136
Chapter 7. Step 3: Cleaning and Lubricating Standards 143
7.1 Aims from the Equipment Perspective 143
7.2 Aims from the Human Perspective 143
x Contents
7.3 How to Develop Step 3 144
7.3.1 Maintain the cleanliness achieved in Step 2 144
7.3.2 Cumulative improvements 144
7.3.3 How to divide a step into substeps 144
7.4 Establish a Lubrication Control System 146
7.4.1 What is lubrication control? 146
7.4.2 Preparation by the maintenance department 147
7.4.3 Launch stepwise activities with lubrication education 147
7.4.4 Identify lubricating points and surfaces 150
7.4.5 Allocate routine lubrication tasks 150
7.4.6 Draw lubrication system flowcharts 151
7.4.7 Set tentative lubricating standards 152
7.4.8 Remedy defective areas and difficult lubricating areas 153
7.4.9 Set cleaning and lubricating standards 154
7.4.10 Thoroughly implement a color lubrication control system 155
7.5 Case Study 158
7.6 The Keypoints of an Autonomous Maintenance Audit 159
7.7 Review the First Stage of the Autonomous Maintenance Program 160
7.7.1 Establish basic equipment conditions 160
7.7.2 Take remedial actions and set standards 160
Chapter 8. Step 4: Overall Inspection 165
8.1 Aims from the Equipment Perspective 165
8.2 Aims from the Human Perspective 165
8.3 The Necessity of Overall Inspection 166
8.3.1 The reality of inspection 166
8.3.2 No motivation is promoted 167
8.3.3 No skill is provided 167
8.3.4 No circumstances are provided 168
8.3.5 An operator s potential 168
8.4 How to Develop an Overall Inspection 171
8.4.1 Overall inspection procedures and substeps 171
8.4.2 Preparing inspection education 172
8.4.3 Conducting overall inspection education 180
8.4.4 Set tentative inspecting standards 181
8.4.5 Restore and improve equipment 181
8.5 Case Study 181
8.5.1 Overall inspection in terms of types of parts 181
8.5.2 Overall inspection in terms of categories 183
8.6 The Keypoints of an Autonomous Maintenance Audit 193
Chapter 9. Step 5: Autonomous Maintenance Standards 195
9.1 Aims from the Equipment Perspective 195
9.2 Aims from the Human Perspective 195
9.3 Finishing the Activities Relating to Equipment 196
9.3.1 Review residual issues 196
9.3.2 Obtain total knowledge about equipment 196
9.3.3 Becoming aware of abnormality by the five senses 197
9.3.4 Thorough implementation of visual controls 198
Contents xi
9.4 How to Develop Step 5 198
9.4.1 Preparatory procedures for autonomous maintenance
standards and substeps 198
9.4.2 Attain given time targets 202
9.5 Routine Inspection by Autonomous Maintenance 202
9.5.1 Determine the allocation of work between the production and
maintenance departments 202
9.5.2 Inspection items and intervals 204
9.5.3 Inspection time 210
9.6 Preparing Autonomous Maintenance Standards 210
9.6.1 Make a suitable combination of cleaning, lubrication, and
inspection 210
9.6.2 How to establish autonomous maintenance standards 211
9.7 Case Study 215
9.7.1 A routine inspection control board 215
9.7.2 Breakdown prevention in a performance tester 215
9.7.3 Breakdown prevention in a pin milling machine 216
9.8 The Keypoints of an Autonomous Maintenance Audit 218
Chapter 10. Step 6: Process Quality Assurance 223
10.1 Aims from the Equipment Perspective 223
10.2 Aims from the Human Perspective 223
10.3 The Challenge of Zero Defects 224
10.3.1 Recent trends 224
10.3.2 Process quality assurance 225
10.3.3 The nature of quality conditions 226
10.3.4 The relationship among quality specifications, quality
causes, and quality results 228
10.3.5 The five quality assurance criteria 229
10.3.6 An approach to Zero Defects 235
10.4 A Prerequisite for Process Quality Assurance 236
10.4.1 Operators roles 236
10.4.2 Materials to be handled by operators 237
10.4.3 What is proper operation? 238
10.4.4 Learn quality control methods 239
10.5 Step 6 1: Remedies Focused on Quality Results 239
10.5.1 How to proceed with remedial actions 239
10.5.2 Step 6 1 1: Prepare a quality assurance flow diagram 240
10.5.3 Step 6 1 2: Assess process quality 243
10.5.4 Step 6 1 3: Take countermeasures to prevent defective
product outflow 244
10.5.5 Step 6 1 4: Products handling 248
10.5.6 Step 6 1 5: Are quality defects detected when they occur? 248
10.6 Step 6 2: Remedies Focused on Quality Causes 249
10.6.1 How to proceed with remedial actions 249
10.6.2 The sequence of countermeasures 250
10.6.3 Step 6 2 1: Raw material control 255
10.6.4 Step 6 2 2: Measuring apparatus control 255
10.6.5 Step 6 2 3: Jig and die control 256
10.6.6 Step 6 2 4: Machining condition control 256
10.6.7 Step 6 2 5: Mistake proof control 256
xii Contents
10.7 Step 6 3: Establish Process Quality Assurance 259
10.8 The Keypoints of an Autonomous Maintenance Audit 259
Chapter 11. Step 7: Autonomous Supervision 263
11.1 TPM Fully Established on the Shopfloor 263
11.2 Maintaining the Current TPM Level 264
11.2.1 Maintaining activity 264
11.2.2 Improving activity 265
11.2.3 Passing on activity 266
11.3 Aiming at a Higher Level of TPM 267
11.3.1 Two types of activity 267
11.3.2 Apply TPM experiences in future products and plant engineering 268
11.3.3 What must be done next? 270
Chapter 12. Autonomous Maintenance in Manual Work Departments 273
12.1 The Basic Concepts of Autonomous Maintenance 273
12.1.1 Autonomous maintenance is applicable to manual work 273
12.1.2 Is repetitive manual work fully improved? 274
12.1.3 The rules must be set by those who follow the rules 275
12.2 How to Develop Autonomous Maintenance 276
12.2.1 Make original plans 276
12.2.2 Identify manual work losses (human errors and quality defects) 277
12.2.3 Specify indexes to measure TPM progress 278
12.3 How to Construct the Seven Step Programs 278
12.3.1 Repeat the CAPD cycle 278
12.3.2 Period 1: Establish basic conditions 279
12.3.3 Period 2: Establish usage conditions of tools and jigs 280
12.3.4 Period 3: Standardization and autonomous supervision 281
12.3.5 Two seven step programs on the same shopfloor 281
12.4 Autonomous Maintenance in the Assembly Department 281
12.4.1 The aims of autonomous maintenance 281
12.4.2 The seven step program for assembly work 283
12.4.3 Case study 287
12.5 Autonomous Maintenance in the Inspection Department 293
12.5.1 The aims of autonomous maintenance 293
12.5.2 The seven step program of autonomous maintenance 298
12.5.3 Case study 304
12.6 Autonomous Maintenance in the Material Handling Department 304
12.6.1 The aims of autonomous maintenance 304
12.6.2 The seven step autonomous maintenance program 305
12.6.3 Case study 305
Glossary 311
Bibliography 319
Index 323
|
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| id | DE-604.BV009854632 |
| illustrated | Illustrated |
| indexdate | 2024-07-09T17:42:02Z |
| institution | BVB |
| isbn | 0070628343 |
| language | English Japanese |
| oai_aleph_id | oai:aleph.bib-bvb.de:BVB01-006523519 |
| oclc_num | 25509059 |
| open_access_boolean | |
| owner | DE-473 DE-BY-UBG DE-634 DE-83 |
| owner_facet | DE-473 DE-BY-UBG DE-634 DE-83 |
| physical | XX, 328 S. Ill., graph. Darst. |
| publishDate | 1992 |
| publishDateSearch | 1992 |
| publishDateSort | 1992 |
| publisher | McGraw-Hill |
| record_format | marc |
| series2 | Industrial and plant engineering |
| spelling | Tajiri, Masaji Verfasser aut TPM suishin no pointo, jishu hozen nanatsu no suteppu TPM implementation a Japanese approach Masaji Tajiri ; Fumio Gotoh New York u.a. McGraw-Hill 1992 XX, 328 S. Ill., graph. Darst. txt rdacontent n rdamedia nc rdacarrier Industrial and plant engineering Plant maintenance Japan Total productive maintenance Qualitätskontrolle (DE-588)4047968-7 gnd rswk-swf Management (DE-588)4037278-9 gnd rswk-swf Produktion (DE-588)4047347-8 gnd rswk-swf Produktion (DE-588)4047347-8 s Management (DE-588)4037278-9 s Qualitätskontrolle (DE-588)4047968-7 s DE-604 Gotoh, Fumio Verfasser aut HBZ Datenaustausch application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=006523519&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis |
| spellingShingle | Tajiri, Masaji Gotoh, Fumio TPM implementation a Japanese approach Plant maintenance Japan Total productive maintenance Qualitätskontrolle (DE-588)4047968-7 gnd Management (DE-588)4037278-9 gnd Produktion (DE-588)4047347-8 gnd |
| subject_GND | (DE-588)4047968-7 (DE-588)4037278-9 (DE-588)4047347-8 |
| title | TPM implementation a Japanese approach |
| title_alt | TPM suishin no pointo, jishu hozen nanatsu no suteppu |
| title_auth | TPM implementation a Japanese approach |
| title_exact_search | TPM implementation a Japanese approach |
| title_full | TPM implementation a Japanese approach Masaji Tajiri ; Fumio Gotoh |
| title_fullStr | TPM implementation a Japanese approach Masaji Tajiri ; Fumio Gotoh |
| title_full_unstemmed | TPM implementation a Japanese approach Masaji Tajiri ; Fumio Gotoh |
| title_short | TPM implementation |
| title_sort | tpm implementation a japanese approach |
| title_sub | a Japanese approach |
| topic | Plant maintenance Japan Total productive maintenance Qualitätskontrolle (DE-588)4047968-7 gnd Management (DE-588)4037278-9 gnd Produktion (DE-588)4047347-8 gnd |
| topic_facet | Plant maintenance Japan Total productive maintenance Qualitätskontrolle Management Produktion |
| url | http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=006523519&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA |
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