OPL – One Point Lesson Template – Free Download

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One Point Lesson is a tool to convey information. Designed to enhance knowledge and skills in a short time, at the right time, whenever needed. To upgrade levels of expertise by having individuals study, learn and then train others in the knowledge or skill. One Point Lesson – Portrait

4M Analysis Process

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The purpose of this procedure is to define the steps to do a 4M Analysis of a system or subsystem. The goal of this 4M Analysis Procedure is to reduce losses in the factory by using the Equipment Attributes as a guideline to achieve this end. 4M Analysis Steps Define

12 Step Kaizen Story

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The Key Tool for Executing Focused Improvement 12 Step Kaizen is a Better Defined CAP-Do Check Identify where the losses are Justify the subject selection by stratifying the data Understand the process and equipment Grasp the actual situation (Identify the Phenomenon) Establish the objective Establish a Work Plan Analyze

5 WHY Analysis, a TPM Tool for Root Cause Analysis (RCA)

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Section 1 5 WHY Process Causes of Losses are Often Complicated: Common Failure scenario: 1. Management system breakdown 2. Failure to implement counter-measures 3. Premature equipment failure 4. Employees fails to follow procedure 5. Failure to ID & Respond 6. Large Loss Results 5 Why Analysis is Proactive Addresses

Autonomous Maintenance Step 4 Training Plan

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Implementation Team 5W 1H WHAT:  Major Stoppages/Breakdowns  WHEN:  Daily WHERE:  Packaging Lines WHO:  Mechanic WHICH:  N/A HOW:  Not Enough time to Eliminate Summary of problem: Mechanics do not have enough time to eliminate major stoppages/breakdowns that occur daily on the packaging lines. Why – Why Analysis WHY-1:  Mechanics are

Principle of Operation – Analysis Diagram

One of the important steps to identify Root Cause is an understanding of process and equipment. To start, create sketch of machine or component, where you saw problem occured. Second step is to identify Ideal Sequence of Movement, e.g. Pickoff arms moves up->Solenoid switching vacuum on->Created suction pulls carton

Broken Parts Museum – Analysing and Preventing Breakdowns due to Forced Deterioration

Collecting broken or worn machine parts for later analysis will help to understand root cause of failures, as well as can assist with training AM team members. Training for AM Teams to Prevent Reoccurrence of Forced Deterioration Breakdowns Use Actual Broken Parts to Demonstrate FD breakdowns to AM teams

Autonomous Maintenance Step 6 and 7 – Standardization and Autonomous Management

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AM – Step 6 Activities – Standardization Objective Standardize Routine Operation to sustain & prevent Problems. Activities Develop Sub-step Activities 6.1 Quality 6.2 Change Over 6.3 Cyclic Operation 6.4 Safety Review the Role of Operators, and Efficiency Improvement and Standardization of Related Work Maintain an Effective Autonomous Inspection System AM –