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

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 NA Equipment Attributes as a guideline to achieve this end. 4M Analysis Steps

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

Chapter 5. Autonomous Maintenance. Part 1

1. Autonomous Maintenance: the Basic Approach 1.1 What is Autonomous Maintenance? (1) Operators should look after their own equipment Autonomous Maintenance aims to create a scenario where all operators look after their own equipment, carrying out routine checks, oiling and greasing, replacing parts, doing simple repairs, spotting problems at

One Point Lesson – OPL

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What is an OPL? 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. Who Creates OPL’s? Everyone! Operators,

Losses Overview

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1. Identify Functions Manufacturing Support is divided across several Functions at a site Each Business Process within these Functions should be clearly identified Some Traditional Functions: In TPM, the functions listed above are some of the traditional focus areas for Manufacturing Support (formerly “TPM in the office”). This focus


Define-Measure-Analyze-Improve-Control is a formal problem-solving process, and a major tool of Lean Six Sigma, based on formula Y= f(X), metric that measures the problem. Define First step is to identify a problem. Lean six sigma approach is to utilize Y=f(X), function defines one variable in terms of another. The statement “y

TPM Pillars

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Total Productive Maintenance focuses on increasing of productivity. By measuring the Overall Equipment Effectiveness, breakdowns and other losses like sub-standard quality, are identified and resolved. Autonomous Maintenance Focused Improvement Planned Maintenance Quality Early Equipment Management Training and Education Manufacturing Support Safety, Health and Environment Autonomous Maintenance (AM) Focused Improvement (FI)

Chapter 2. Losses, Costs and Efficiency

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Losses in Production System Figure 2.1 shows the structure of the losses inherent in a typical production system. These losses can be split into three main categories: those preventing equipment from being used as efficiently as it could (The 8 Big Equipment Losses, at the upper right of the