My Home page is Japanese Gemba Kaizen Web
http://takuminotie.com/english/
Please Look and Like us on Facebook
Table of contents
1. Improvement of zero failure
2. Improvement of the setup
3. Improvement of cutting blade change loss
4. Improvement of start up
5. Improvement of Minor stoppage
6.Improvement of Speed losses
7.Improvement of Yield losses
8. Principle of improvement
Total Quality Managment - TPM - final year B.E.cs - Presented by DR. K. BARANIDHARAN, SAIRAM INSTITUTE OF MANAGMENT STUDIES (sims) SRI SAI RAM INSTITUTE OF TECHNILIGY (sit) CHENNAI
My Home page is Japanese Gemba Kaizen Web
http://takuminotie.com/english/
Please Look and Like us on Facebook
Table of contents
1. TPM Concept
2. TPM Definition
3. TPM Philosophy
4. TPM Essence
5. Improvement lead to real benefits
6 .Case of small amount of work
7.TPM organization
8. TPM History
9.TQC&TPM
10. Step 12 of the TPM program
11.8 main pillars of TPM
12. Participation of all employees activities
13. TPM Promotion Organization
14. Case of TPM promotion organizations
15. TPM basic policy and Goal
16. Ask the machine
TPM for lean manufacturing chp4 step of “jlshu hozen “activities博行 門眞
My Home page is Japanese Gemba Kaizen Web
http://takuminotie.com/english/
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Table of contents
1. What is Jlshu-Hozen ?
2.Conservation activities of manufacturing departments
3.Conservation activities of maintenance department
4.Step method for the development of “Jishu-Hozen”
Step1: Initial-phase cleaning
Step2:Countermeasures for the source of problems
Step3: Establishment of tentative standards for“Jishu-Hozen”
Step4:General [overall] inspection
Step5: Autonomous inspection
Step6:Standardization
Step 7:Thorough implementation of autonomous
Total Quality Managment - TPM - final year B.E.cs - Presented by DR. K. BARANIDHARAN, SAIRAM INSTITUTE OF MANAGMENT STUDIES (sims) SRI SAI RAM INSTITUTE OF TECHNILIGY (sit) CHENNAI
My Home page is Japanese Gemba Kaizen Web
http://takuminotie.com/english/
Please Look and Like us on Facebook
Table of contents
1. TPM Concept
2. TPM Definition
3. TPM Philosophy
4. TPM Essence
5. Improvement lead to real benefits
6 .Case of small amount of work
7.TPM organization
8. TPM History
9.TQC&TPM
10. Step 12 of the TPM program
11.8 main pillars of TPM
12. Participation of all employees activities
13. TPM Promotion Organization
14. Case of TPM promotion organizations
15. TPM basic policy and Goal
16. Ask the machine
TPM for lean manufacturing chp4 step of “jlshu hozen “activities博行 門眞
My Home page is Japanese Gemba Kaizen Web
http://takuminotie.com/english/
Please Look and Like us on Facebook
Table of contents
1. What is Jlshu-Hozen ?
2.Conservation activities of manufacturing departments
3.Conservation activities of maintenance department
4.Step method for the development of “Jishu-Hozen”
Step1: Initial-phase cleaning
Step2:Countermeasures for the source of problems
Step3: Establishment of tentative standards for“Jishu-Hozen”
Step4:General [overall] inspection
Step5: Autonomous inspection
Step6:Standardization
Step 7:Thorough implementation of autonomous
TPM the effective maintenance with Autonomous MaintenanceTimothy Wooi
This is a 2 days course on Total Productive Maintenance (TPM) that will guide you through to implement Autonomous Maintenance (AM) on your current Equipment and to plan the execution of your Preventive (PM) & Predictive Maintenance (PdM).TPM defines your Maintenance schedule and Goals. TPM helps you plan and develop the optimal program for your facility, resulting in increased efficiency and cost savings.
Day 1
TPM General Overview with Autonomous
Maintenance (AM) as the back bone of TPM
6 Steps to Autonomous Maintenance
Audit , Review & Externalize Inspection Activities
from Equipment Manual to (AM)
Executing Equipment Audit to start (AM) & (PM)
-TPM Board & AM Checklist with Visual
Management Implementation.
Many companies found a reality gap between the hype versus the reality when implementing TPM. Over 21 yrs of TPM consulting for 25 MNCs I found 2 consistent reasons. (1) Failure to understand the Pillar Details and Pillar linkages. (2) Under-estimating TPM resource requirements.
Please enjoy this highly condensed presentation. Be enriched and blessed.
A presentation on TPM and its goals, pillars, and other aspects have been explored as well as its relation to 5s, OEE these tools also have been shown. In the end, step by step implementation of TPM is also discussed.
[Note: To download this poster, visit:
https://www.oeconsulting.com.sg/training-presentations]
The poster depicts the 8 steps of Focused Improvement (Kobetsu Kaizen).
Autonomous Maintenance (Jishu Hozen) by Ketan Kumar (Raavinnovate)KetanKumar43
This file contains brief introduction about Autonomous Maintenance (a pillar of TPM) which also known as My Machine my concept. In this the Goal for AM, History of AM, Benefits of AM, OEE, 7 basic types of abnormalities and steps of Autonomous Maintenance are discussed along with pictorial examples, CLIT, SOP, etc are also illustrated.
Quality Maintenance is an "advanced" pillar of TPM and aims to assure zero defect conditions. Also known as Hinshitsu Hozen in Japanese, it does this by understanding and controlling the process interactions between the 4Ms - manpower, material, machines and methods that could enable defects to occur. The key is to prevent defects from being produced in the first place, rather than screening them out through inspection systems after they have been produced. Controlling quality through its causes is the essence of Quality Maintenance.
Developed by our JIPM-certified TPM Instructor, this presentation teaches the key concepts, principles and philosophy of Quality Maintenance, the 4M conditions that are essential for defect-free production, as well as the step-by-step process for Quality Maintenance.
LEARNING OBJECTIVES
1. Understand the key concepts, principles and philosophy of Quality Maintenance
2. Acquire knowledge on the 4M conditions and the prerequisites for promoting Quality Maintenance
3. Describe the 8-step process of Quality Maintenance and the key analytical tools and techniques
CONTENTS
1. Key Concepts & Philosophy of Quality Maintenance
2. 4M Conditions - The Determinants of Quality
3. The 8 Steps of Quality Maintenance
4. Key Tools & Techniques for Quality Maintenance
5. Towards Excellence in Quality Maintenance
To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations
Introduce Japanese Kaizen lean manufacturing
My Home page renewaled http://www.takuminotie.com/english/
Please Like us on Facebook and Introduce to your Friends.
Regurds.
Table of Content
Practical Use of Current System
Learning and Creative Choice
Turning Knowledge Into Wisdom
Kaizen’s Standard Tactics of Application of ○
Kaizen of Functional Utilization
Kaizen of Auxiliary Tools
The 3 Stages of The Application of Auxiliary Tool
Kaizen of Can Be Done by One Person
TPM For lean manufacturing chp 2 | concept of production efficiency | lea...博行 門眞
My Home page is Japanese Gemba Kaizen Web
http://takuminotie.com/english/
Please Look and Like us on Facebook
Table of contents
1.What is the production efficiency?
2. 8 large loss to inhibit efficiency
3. Seven large loss of equipment
4. Sudden loss and chronic loss
5. Restoration
6. Cleaning is inspection
7. Equipment Ideal
8. Minaor defects
9. PM Analysis
10. maintenance skills
TPM the effective maintenance with Autonomous MaintenanceTimothy Wooi
This is a 2 days course on Total Productive Maintenance (TPM) that will guide you through to implement Autonomous Maintenance (AM) on your current Equipment and to plan the execution of your Preventive (PM) & Predictive Maintenance (PdM).TPM defines your Maintenance schedule and Goals. TPM helps you plan and develop the optimal program for your facility, resulting in increased efficiency and cost savings.
Day 1
TPM General Overview with Autonomous
Maintenance (AM) as the back bone of TPM
6 Steps to Autonomous Maintenance
Audit , Review & Externalize Inspection Activities
from Equipment Manual to (AM)
Executing Equipment Audit to start (AM) & (PM)
-TPM Board & AM Checklist with Visual
Management Implementation.
Many companies found a reality gap between the hype versus the reality when implementing TPM. Over 21 yrs of TPM consulting for 25 MNCs I found 2 consistent reasons. (1) Failure to understand the Pillar Details and Pillar linkages. (2) Under-estimating TPM resource requirements.
Please enjoy this highly condensed presentation. Be enriched and blessed.
A presentation on TPM and its goals, pillars, and other aspects have been explored as well as its relation to 5s, OEE these tools also have been shown. In the end, step by step implementation of TPM is also discussed.
[Note: To download this poster, visit:
https://www.oeconsulting.com.sg/training-presentations]
The poster depicts the 8 steps of Focused Improvement (Kobetsu Kaizen).
Autonomous Maintenance (Jishu Hozen) by Ketan Kumar (Raavinnovate)KetanKumar43
This file contains brief introduction about Autonomous Maintenance (a pillar of TPM) which also known as My Machine my concept. In this the Goal for AM, History of AM, Benefits of AM, OEE, 7 basic types of abnormalities and steps of Autonomous Maintenance are discussed along with pictorial examples, CLIT, SOP, etc are also illustrated.
Quality Maintenance is an "advanced" pillar of TPM and aims to assure zero defect conditions. Also known as Hinshitsu Hozen in Japanese, it does this by understanding and controlling the process interactions between the 4Ms - manpower, material, machines and methods that could enable defects to occur. The key is to prevent defects from being produced in the first place, rather than screening them out through inspection systems after they have been produced. Controlling quality through its causes is the essence of Quality Maintenance.
Developed by our JIPM-certified TPM Instructor, this presentation teaches the key concepts, principles and philosophy of Quality Maintenance, the 4M conditions that are essential for defect-free production, as well as the step-by-step process for Quality Maintenance.
LEARNING OBJECTIVES
1. Understand the key concepts, principles and philosophy of Quality Maintenance
2. Acquire knowledge on the 4M conditions and the prerequisites for promoting Quality Maintenance
3. Describe the 8-step process of Quality Maintenance and the key analytical tools and techniques
CONTENTS
1. Key Concepts & Philosophy of Quality Maintenance
2. 4M Conditions - The Determinants of Quality
3. The 8 Steps of Quality Maintenance
4. Key Tools & Techniques for Quality Maintenance
5. Towards Excellence in Quality Maintenance
To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations
Introduce Japanese Kaizen lean manufacturing
My Home page renewaled http://www.takuminotie.com/english/
Please Like us on Facebook and Introduce to your Friends.
Regurds.
Table of Content
Practical Use of Current System
Learning and Creative Choice
Turning Knowledge Into Wisdom
Kaizen’s Standard Tactics of Application of ○
Kaizen of Functional Utilization
Kaizen of Auxiliary Tools
The 3 Stages of The Application of Auxiliary Tool
Kaizen of Can Be Done by One Person
TPM For lean manufacturing chp 2 | concept of production efficiency | lea...博行 門眞
My Home page is Japanese Gemba Kaizen Web
http://takuminotie.com/english/
Please Look and Like us on Facebook
Table of contents
1.What is the production efficiency?
2. 8 large loss to inhibit efficiency
3. Seven large loss of equipment
4. Sudden loss and chronic loss
5. Restoration
6. Cleaning is inspection
7. Equipment Ideal
8. Minaor defects
9. PM Analysis
10. maintenance skills
Introduce Japanese Kaizen lean manufacturing
My Home page renewaled http://www.takuminotie.com/english/
Please Like us on Facebook and Introduce to your Friends.
Regurds.
Table of Content
1.What is Kaizen?
2. The History of Kaizen
・History and philosophy of Toyota Production System
・The Philosophy of Toyata Production
・The Kanban System
・“Automation with A Human Touch”
・Muda (Waste) Elimination
・The Mind of Toyota's manufacturing
3. The Kaizen Philosophy
4.How to proceed Kaizen?
5. Kaizen & Innovation
6. Practical Kaizen System
Gemba Kaizen for lean manufacturing chap2 | kaizen collection of cases | lea...博行 門眞
Introduce Japanese Kaizen lean manufacturing
My Home page renewaled http://www.takuminotie.com/english/
Please Like us on Facebook and Introduce to your Friends.
Regurds.
Table of Content
Kaizen example: Boxing
Kaizen example: Airborne Dust
Kaizen example: Cup Noodles
Kaizen Example of Visualization ①
Kaizen Example of Visualization ②
Kaizen Example of Visualization ③
Kaizen Example of Visualization ④
Kaizen Example of Visualization ⑤
Kaizen Example of Visualization ⑥
Kaizen Example of Visualization ⑦
[Note: This is a partial preview. To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations]
The goal of Total Productive Maintenance (TPM) is to increase equipment effectiveness so that each piece of equipment can be operated to its full potential and maintained at that level. To maximize equipment effectiveness, you need a measurement tool that can help you understand your equipment problems so that you can take steps to eliminate them. The key to this understanding is Overall Equipment Effectiveness (OEE).
OEE is a crucial measure in TPM that tells you how well your equipment is running. It links three elements in one percentage: the time the machine is actually running, the quantity of products the machine is turning out, and the quantity of good output.
LEARNING OBJECTIVES
1. Understand the concept and philosophy of TPM and its relationship with OEE
2. Explain the importance of OEE and how it relates to value-adding work of the factory
3. Understand OEE concepts such as Availability, Performance, Quality and the Six Major Losses
4. Describe the steps of collecting and processing OEE data and reporting results
5. Define approaches for reducing equipment-related losses to raise OEE
To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations
[Note: To download the complete presentation, visit:
https://www.oeconsulting.com.sg/training-presentations]
Total Productive Maintenance (TPM) is a comprehensive approach to equipment maintenance that aims to optimize equipment efficiency, reliability, and performance. It involves a holistic approach to maintenance, encompassing both the technical and the human aspects of equipment management. TPM is often associated with Lean Manufacturing, which emphasizes the elimination of waste and continuous improvement.
The primary objective of TPM is to improve equipment effectiveness by minimizing downtime, reducing defects, and increasing overall equipment efficiency. This is achieved through the implementation of a set of maintenance strategies that involve both the equipment operators and maintenance staff. TPM has several benefits, including increased productivity, reduced downtime, improved quality, increased safety, and improved morale among employees.
Our TPM presentation is created by a certified JIPM TPM consultant and delivers a comprehensive training experience. Covering the TPM tools, 5S, OEE (Overall Equipment Effectiveness), and the eight pillars with a focus on Autonomous and Planned Maintenance, this detailed presentation outlines the step-by-step process for TPM implementation. By incorporating practical examples and real-world applications, this presentation provides an engaging and effective way to introduce and implement TPM in your organization.
LEARNING OBJECTIVES
1. Understand the concept and management philosophy of TPM as a foundation for Lean Transformation
2. Learn the 8 pillars of TPM activities, TPM implementation strategy, roadmap and step-by-step approach
3. Learn the TPM tools and be able to identify and eliminate loss through TPM implementation
4. Learn how to kick-start TPM deployment with the key pillars such as Autonomous Maintenance, Planned Maintenance, Focused Improvement and Education & Training activities to improve equipment reliability
5. Understand the roles of a TPM implementation organization and the critical success factors
Currently, "Windy" is the No. 1 weather app that is popular for fishing, surfing, diving, and mountaineering.
Sometimes, the best way to understand the weather around you is to see it visualized on your phone screen. That's what Windy offers with detailed maps that let you watch the weather forecast unfold in front of you.
Windy excels at wind patterns, of course, but the app has 40-plus maps available showing temperature, humidity and more. You've also got satellite and Doppler info at your fingertips, plus a hurricane tracking feature that comes in handy during storm season.
Windy is a Czech company providing interactive weather forecasting services worldwide.
The portal was founded by Ivo Lukačovič in November 2014. Initially, the portal focused on wind animation, currently there are other basic meteorological parameters such as temperature, pressure, relative humidity, cloud base and additional panels with more advanced data.
Windy also has a website as well as a free app available for iPhone and Android.
IoTは「Internet of Things」順略称で、日本語では「モノのインーネット」と訳されます。ここでいう「モノ」とはネットワークにつながることが可能な私たちのまわりにある身近な物です。たとえば、今あなたが身に着けている服や時計、家電や車、もしくは家自身、さらには今あなたが読んでいる本書も、ネットワークにつながれば、IoTでいうところの「モノ」になります。
Overview of the fundamental roles in Hydropower generation and the components involved in wider Electrical Engineering.
This paper presents the design and construction of hydroelectric dams from the hydrologist’s survey of the valley before construction, all aspects and involved disciplines, fluid dynamics, structural engineering, generation and mains frequency regulation to the very transmission of power through the network in the United Kingdom.
Author: Robbie Edward Sayers
Collaborators and co editors: Charlie Sims and Connor Healey.
(C) 2024 Robbie E. Sayers
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptxR&R Consult
CFD analysis is incredibly effective at solving mysteries and improving the performance of complex systems!
Here's a great example: At a large natural gas-fired power plant, where they use waste heat to generate steam and energy, they were puzzled that their boiler wasn't producing as much steam as expected.
R&R and Tetra Engineering Group Inc. were asked to solve the issue with reduced steam production.
An inspection had shown that a significant amount of hot flue gas was bypassing the boiler tubes, where the heat was supposed to be transferred.
R&R Consult conducted a CFD analysis, which revealed that 6.3% of the flue gas was bypassing the boiler tubes without transferring heat. The analysis also showed that the flue gas was instead being directed along the sides of the boiler and between the modules that were supposed to capture the heat. This was the cause of the reduced performance.
Based on our results, Tetra Engineering installed covering plates to reduce the bypass flow. This improved the boiler's performance and increased electricity production.
It is always satisfying when we can help solve complex challenges like this. Do your systems also need a check-up or optimization? Give us a call!
Work done in cooperation with James Malloy and David Moelling from Tetra Engineering.
More examples of our work https://www.r-r-consult.dk/en/cases-en/
Explore the innovative world of trenchless pipe repair with our comprehensive guide, "The Benefits and Techniques of Trenchless Pipe Repair." This document delves into the modern methods of repairing underground pipes without the need for extensive excavation, highlighting the numerous advantages and the latest techniques used in the industry.
Learn about the cost savings, reduced environmental impact, and minimal disruption associated with trenchless technology. Discover detailed explanations of popular techniques such as pipe bursting, cured-in-place pipe (CIPP) lining, and directional drilling. Understand how these methods can be applied to various types of infrastructure, from residential plumbing to large-scale municipal systems.
Ideal for homeowners, contractors, engineers, and anyone interested in modern plumbing solutions, this guide provides valuable insights into why trenchless pipe repair is becoming the preferred choice for pipe rehabilitation. Stay informed about the latest advancements and best practices in the field.
COLLEGE BUS MANAGEMENT SYSTEM PROJECT REPORT.pdfKamal Acharya
The College Bus Management system is completely developed by Visual Basic .NET Version. The application is connect with most secured database language MS SQL Server. The application is develop by using best combination of front-end and back-end languages. The application is totally design like flat user interface. This flat user interface is more attractive user interface in 2017. The application is gives more important to the system functionality. The application is to manage the student’s details, driver’s details, bus details, bus route details, bus fees details and more. The application has only one unit for admin. The admin can manage the entire application. The admin can login into the application by using username and password of the admin. The application is develop for big and small colleges. It is more user friendly for non-computer person. Even they can easily learn how to manage the application within hours. The application is more secure by the admin. The system will give an effective output for the VB.Net and SQL Server given as input to the system. The compiled java program given as input to the system, after scanning the program will generate different reports. The application generates the report for users. The admin can view and download the report of the data. The application deliver the excel format reports. Because, excel formatted reports is very easy to understand the income and expense of the college bus. This application is mainly develop for windows operating system users. In 2017, 73% of people enterprises are using windows operating system. So the application will easily install for all the windows operating system users. The application-developed size is very low. The application consumes very low space in disk. Therefore, the user can allocate very minimum local disk space for this application.
Water scarcity is the lack of fresh water resources to meet the standard water demand. There are two type of water scarcity. One is physical. The other is economic water scarcity.
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
Sachpazis:Terzaghi Bearing Capacity Estimation in simple terms with Calculati...Dr.Costas Sachpazis
Terzaghi's soil bearing capacity theory, developed by Karl Terzaghi, is a fundamental principle in geotechnical engineering used to determine the bearing capacity of shallow foundations. This theory provides a method to calculate the ultimate bearing capacity of soil, which is the maximum load per unit area that the soil can support without undergoing shear failure. The Calculation HTML Code included.
Pile Foundation by Venkatesh Taduvai (Sub Geotechnical Engineering II)-conver...
TPM For lean manufacturing chp3 | kobetsu kaizen for production efficiency | lean tools
1. 1
TPM for lean manufacturing
Chap3. Kobetsu-kaizen for production efficiency
Quote From :TPM Deployment program
TPM encyclopedia Keyword Book
(Japan Institute of Plant Maintenance)
Created by Japanese Gemba Kaizen Web
2. 2
3. Kobetsu-kaizen for production
efficiency
3.1 ・・・ Improvement of zero failure ・・・・・P38
3.2 ・・・ Improvement of the setup ・・・・・P43
3.3 ・・・ Improvement of cutting blade change loss・・・47
3.4・・・ Improvement of start up ・・・・・P50
3.5・・・ Improvement of Minor stoppage ・・・・・P52
3.6・・・ Improvement of Speed losses ・・・・・P56
3.7・・・ Improvement of Yield losses・・P58
3.8・・・ Principle of improvement ・・・・・・P60
3. “Kobetsu-Kaizen" refers to the “individual
improvement for further efficient
production systems." It means efforts to
select model equipment or a model line
and to challenge the target of zero losses
through project team
activities according to improvement
themes.
“Kobetsu-Kaizen" takes the form of
activities through project teams composed
of managerial staff members and through
small workshop
groups.
The procedures for the implementation of
“Kobetsu-Kaizen" by managerial stall
members are as follows:
[1] Selection of model equipment
Model equipment or a model line should be
chosen.
[2] Organization of a project team
A team of several members should be
organized, with the line manager in
charge of the model equipment serving as its
leader.
[3] Grasping and confirmation of 16 major
losses
[4] Decision on the theme and preparation of a
promotion program
[5] “Kobetsu-Kaizen" project activities
For these activities, failure analysis methods
and IE methods should be
utilized. For chronic losses, PM analysis should
be applied.
[6] Standardization and horizontal evolution
should be completed for enhancement of OEE
3
4. 4
3.1 Improvement of zero failure
3・1・1 Common challenges related to failure
(1) No interest production Section
・ The worker is not anything other than work
・ For safety reasons, worker does not touch the equipment
・ There is no provision
(2) Failure analysis is poor
・They have not drawn broken parts
・ They dose not have to disassemble the defective part
・They only exchange parts
・No relapse prevention
Workers just do not know how to Maintenance
If Teach Maintenance to Wokers ,They can .
Maintenance personnel does not understand the function of the parts
They does not understand Why-Why analysis
5. 5
(3) Maintenance system is incomplete
・Judgment standard ,method of inspection , inspection points is incomplete
・Defective Maintenance schedule
・ Record system of failure
(4) Predictive maintenance is poor
・Periodically measuring equipment to determine the abnormality
・ Precision diagnosis ・・・Measure vibration, current load, timing, operating time,
sound, etc and then understand the change point
If there is no data management can not be right!
6. 6
3・1・2 Thinking reduction of failure
(1) Classification of failure
・failure Classified simple and complex then Give priority to simple failure
・ Method of stratified ・・・Mode causes / line/Occurrence location
(2) Failure analysis
・Stress on the equipment
→ Electric or mechanical stress, temperature, humidity, dust, vibration,
Cause failure :
· deficiencies basic conditions
· Do not keep the terms and conditions
· Degraded without Restore
· lowering skill
· Lack of design
Intensity <Stress
Failure occurrence
To educate and Change the way of thinking
and Change their behavior
7. 3・1・3 Four phases to achieve zero failures
Four phases to achieve zero failures
A short-term and simultaneous implementation
of the five measures for zero breakdowns is
unlikely to progress smoothly. It is more effective
to divide enforcement of the measures into four
phases and implement them one by one under a
plan. Through these steps, steady approach to
zero failures will become possible.
The four phases and principal themes of
individual themes are as follows:
~ Phase 1: To reduce dispersion of MTBF —
mean time between failures.
Repair of previous uncovered but unamended
degradation to restore the original conditions,
preparation of basic conditions, and
prevention of artificial machine deterioration
through observance of usage conditions.
- Phase 2: To extend inherent service life.
Improvement of design shortcomings (corrective
maintenance),prevention of random failure
occurrences due to operation or repair errors,
and restoration by fixing external appearance
deterioration.
- Phase 3: To periodically repair deterioration to
restore original conditions.
Regular deterioration repair to restore the
original conditions
periodic maintenance: TBM), and grasping of
abnormal symptoms
of internal deterioration based on the five senses.
- Phase 4: To foresee the service life.
Prediction of the service life based on condition
diagnosis
techniques (predictive maintenance: CBM), and
technological
analysis of catastrophic failures.
7
8. 3・1・4 Five measures to achieve zero failures
Failures represent only the tip of the iceberg, so
to speak. The leaving of
latent defects below the “water surface" causes
failures.
Methods for uncovering such latent defects and
preventing failures are the
"five measures to achieve zero failures, "and
they are as follows:
[1] Put basic conditions in place:
Keeping of basic conditions for equipment, i.e.,
enforcement of cleaning,oiling, and retightening
(of bolts and nuts).
l2] Abide by operational conditions:
Observance of the specified operational
conditions of the equipment, such
as pressure, temperature, speed, and flow rate.
[3] Restore original functions by fixing
deterioration:
The prevention of forced deterioration of
quipment is possible by preparing basic
conditions and abiding by usage conditions.
Even so,natural deterioration, such as wear,
corrosion, fatigue, and declining insulation,
inevitably occurs. Therefore, such deterioration
should not be left unattended but corrected to
restore the original conditions.
l4] Improve design weaknesses:
Only repeating correction of deterioration cannot
lead to progress. To begin with, deterioration
may be accelerated due to material selection
errors or structural defects during design stage.
Such design shortcomings must be rectified
(this is corrective maintenance).
' l5] "Improve skills:
8
Ask to
the machine
cleaning,oiling, and retightening is Important
9. 9
3.2 Improvement of the setup
This is one of the seven major losses that
impede equipment operations and
refers to the time lost from the
termination of the production of a
present item until the good-quality
manufacturing of the next item
subsequent to setup and adjustment.
The setup here means a series of work:
removal of jigs/tools upon the completion
of the on-going production, clearing up,
cleaning; preparation,attachment,
adjustment, and measurement of
jigs/tools required for the next item
and manufacturing of non-defective
products.
There remain many issues to be
addressed to shorten the time spent
on ‘internal setup’ (setup during
machine stoppage) and ‘external
setup’ (setup without machine
stoppage) based on IE approach.
Adjustment means the following:
[1] Measures to be taken to seek the
optimum solutions or values to attain
some purpose; for instance, the
procedures to put quality within
designed values
[2] What is achieved through the
repetit ion of trial and errors
Understand the setup, to quantify !
10. 10
(1) Organize and tidy
・ Management position of tooling
・ Do not search, do not move
(2) Clarification External setup and Inter
setup
・ Study Elimination of work-
・ Review of work procedures
(3)Study External setup to Inter setup
・Preset(Pre-assembled)
・ Sharing of jig and Exchange one-touch
・ Changes the adjustment to External
setup
・Using the auxiliary jig・・・The elimination
of adjustment
(4) Study procedures of Inter setup
・Study on method of fixation Screw fixing
→ Hydraulic
・ One worker → Two worker Time
savings
(5) The elimination of adjustment
· The purpose of the adjustment
① positioning
② centering
③ the correct dimensions
④ timing
⑤ balance
-Cause of the adjustment
① cumulative error
② shortage standardization
③ shortage rigidity
Analysis of adjustment
Study the one-touch setup
Study eliminating waste of External setup and Inter setup
3・2・2 Improvement of the setup
13. 13
3.3 Improvement of cutting blade change loss
3.3.1- Problem of cutting blade
(1)The life of the cutting tool
・Shape and material of the cutting tool
· Cutting conditions (cutting speed)
・Material, hardness
・requirements of Quality product
(Dimensional accuracy, surface roughness)
・Rigidity of the equipment
Look the cutting edge!
14. 14
(2)Exchange conditions
Reason:
・Unclear Exchange standards
・Failure occurs,
Exchange without permission
(3)Inhibiting unattended operation
Reason:
・varies Quality ・Short-cutting tool life
・Occurs Minor Stoppage
(4) Reduction of cutting tool’s cost
・Storing the old chip
・ No management objectives of cost cutting tool
・ Many kinds of cutting tool
・Management chip is loose
・ No historical record use of a chip
・ No Management abrasion of the chip
(Can be use but exchange can not use but No exchange)
15. 15
Detection parameters of the cutting tool life
Quantify sound, vibration, AE, resistance, current, heat
16. Start-up losses denotes the time losses and
volume losses (from defects and remark)
until product quality stabilizes to
manufacture non-defective products even in
accordance with the specified cycle time
without mechanic troubles, such as minor
stoppages, small troubles, and breakage of
cutting blades, during
[1] start-up after periodic overhaul
[shutdown maintenance]
[2] start-up after downtime (long-term line
stoppage)
[3] start-up after holidays
[4] start-up after the lunch break.
At a machining shop dimension dispersions
are likely to occur during the morning setup,
causing frequent adjustments, rework due to
failure to
adjustment, and breakdown of cutting
blades. To prevent these, warm-up and
idling operations are conducted early in the
morning. The target of
start-up losses is “minimization.”
16
3.4 Improvement of start up
Understanding the thermal displacement!!
17. 17
3.4.2 Improvement Way of start up
(1) measure:
・Measuring temperature of the table, Main shaft, etc to stabilize.
(2) Study Material :
・Consult the manufacturer the material to minimize thermal displacement
(3) Cooling the generator
・ Cool heat by Cooling fan
(4) Automatic correction
・Automatically adjusts to predict beforehand the amount of displacement
Study Cause,Thermal displacement curve,Time to settle
18. 18
3.5 Improvement of Minor stoppage losses
[1] In case temporary functional
stoppage ensues.
[2] in case the recovery of functions is
made by simple fixing
(elimination of abnormal work-
piece and/or resetting)
[3] ln case parts exchange or repair
are not required.
[4] Recovery time lasts from 2 or 3
seconds less than 5 minutes.
Unlike failures, minor stoppage/idling
losses represent a status in
which the machine is subjected
to either stoppage or idling due
to temporary troubles; for
instance, when a work-piece is
clogged in the chute, idling
occurs ; or when a sensor activated
because of a quality defect to
cause a temporary stoppage.
These are the conditions in which the
machine will revert to normal
operation, if the stuck work-
piece is removed, or resetting is
carried out. Therefore, they are
fundamentally different from
machine failures.
To reduce minor stoppages, it is
important to in detail analyze
phenomena [or slight defects]
and to thoroughly eliminate
slight defects.
Observation, analysis, stratified to investigate at the site
19. 19
3.5.2. Improvement Way of Minor stoppage
losses
(1) Phenomenon analysis and motion analysis of workpiece:
Video recording the phenomenon of Minor stoppage , Viewpoint is movement
posture, angle, float, vibration
(2) Remediation of the defect:
Contact surface of the workpiece is key point
Improve the small defects of parts and jigs
(3)Compliance with the basic maintenance:
Cleaning, refueling, retightening
(4) Compliance with of the basic tasks:
Correct operation, setup, adjustment
(5)Study on optimum condition:
Studied the optimization of processing conditions of Parts
(6)Study Weakness:
Studied the problem of the design of equipment、parts,jigs
Understand the movement of the workpiece by video shoot
22. 22
3.6 Improvement of Speed losses
Into the data to understand the current status of equipment!
One of the seven major losses impeding
efficiency improvement of equipment. These
losses incurred by slow machine speed are
defined as
follows:
[1] Losses due to the difference between the
actual speed and the design
speed (or reference speed for each product
item)
[2] Losses resulting from lower design speed
compared to the present technological level or
desirable speed
(or ‘mission’ speed)
As an example of the former case, the cycle
time is 60 seconds as reference but the actual
operation cycle time is 65 seconds. There is a
speed loss of 5 seconds. As an example of the
latter case, the cycle time is set at 60 seconds
but it could be reduced to 50 seconds through
improvement based on the current
technological level. There is a speed loss of
10 seconds in this case.
Aiming at speed increase would contribute to
clarification of problems and
upgrading of technological levels. Therefore,
the target should be to make
nit the difference between the design speed
and the actual speed.
23. 23
3.6.2 How to improve the speed loses
(1)Understand the cause
To speed up For the experiment.
① Changes in Cp ?
② New bad item ?
③ The life of the cutting tool ?
④ Number of occurrences of Minor Stoppage?
⑤ Percentage occurrence of defective ?
*Examine the aggravating factors measures ahead
(2)Check the validity of the action
①Reduction of air cut time
②Reduction of idle time ③Reduction of operating time ④ Reduction of working hours by two
people work
*Make improvement on equipment mechanism, component structure, timing, the cycle diagram.
Study Air cut time,Idle time,Operating time,Two person work
24. 24
3.7 Improvement of Yield losses
This refers to the volume losses resulting from
differences between raw material weight
and product weight, or between raw
materials input and product weight.
The former represents material losses that can
result from leaving too much iron cast for
fear of casting shortcomings (such as sand
inclusion) or from forging too thick so that it
may be sufficient enough to obtain mold
precision in the shaping process.
As a result of these, cutting time can be
lengthened, or the service life of cutting
blades shortened.
The latter represents the difference between
whitewash weight, gate weight, generated
burr volume and the product weight. in
other words, the losses in this category
result from increased burr generation due
to molding precision insufficiency.
in the case of aluminum casting, this refers to
the
losses representing runner weight and blur
Weight.
25. 25
3.7.2 How to to reduce chronic defects
(1)Immobilization of variable factors
factors?:Impact phenomena logically
Cause?:Which have proved to have influenced the phenomenon
“Restore ,For Immobilizing the "Variation factor"!!
27. 27
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