Process Excellence
What is Error-Proofing or Poka-Yoke
A strategy of implementing “fail-safe mechanisms” to prevent a process from producing defects.A timeless common-sense concept that was more recently popularized by Japanese industrial engineer Shigeo Shingo. Error-proofing is a philosophy whereby it is unacceptable to make even a very small number of defects or mistakes, and the only way…
Read More »Planned Maintenance Case Study, Food Processing Plant
This case study shows the progress of the Planned Maintenance Pillar of a food manufacturing facility between 2016 and 2020 (3rd quarter results).The facility is located in North America. Situation Before TPM Analysis of the situation was done using 4M methodology: Man Low level of skillsPeople with high stressLow spirit…
Read More »World Class Manufacturing PM – Machine Ledger and PM Calendar
7 steps of PM Step 1. Elimination of forced deterioration and prevention of accelerated deteriorationStep 2. Reverse deterioration (Breakdown Analysis)Step 3. Establishment of maintenance standardsStep 4. Countermeasures against weak points of the machine and lengthened equipment lifeStep 5. Build a periodic maintenance systemStep 6. Build a predictive maintenance system (trend management)Step 7. Maintenance cost management. Establishment…
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5S Audit Checklist and Report
Randomly scheduled audits for compliance are essential to sustain a 5S environment. Frequency of audit dependent on “traffic”, “risk”, demonstrated compliance (sustaining efforts, past audits), etc.
