TPM Book. 3.Focused Improvement

(c) “TPM in Process Industries”. Edited by Tokutaro Suzuki

1. What is focused improvement?

Focused improvement includes all activities taht maximize the overall effectiveness of equipment, processes, and plants through uncompromising elimination of losses and improvement performance. Focused improvement is implemented systematically as projects.

2. Losses and the Six Major Results

Major losses: equipment failure, process failure, idling and minor stoppage, speed, process defect, startup and yield, energy, quality deffect, leakage and spillage, manual work.

Major results: production, cost, safety, quality, delivery, morale

3. Focused Improvement in Practice

Adopt a Macro Approach, be “zero-oriented”, siplify equipment, raise the level of engineering technology.

4. The Step-by-Step Approach to FI

Step 0: Select an improvement topic and form project team

Step 1: Understand situation

Step 2: Expose and eliminate abnormalities

Step 3: Analyze causes

Step 4: Plan improvement

Step 5: Implement improvement

Step 6: Check results

Step 7: Consolidate gains

5. Analytical Techniques for Improvement

P-M analysis (phenomena are analyzed in terms of their physical principles)
Know-why analysis (also called “why-why analysis”)
Fault-tree analysis (FTA)
Failure mode and effect analysis (FMEA)
Industrial engineering (IE)
Value analysis (VA)
Just-in-time production (JIT) (Toyota production system)
The original seven QC tools and seven new QC tools (also called the seven management tools)
6. P-M Analysis

P – phenomenon, physical, M – Mechanism, 4Ms (eqiupment, materials, people, methods)

P-M Analysis Steps:

Clarify phenomena
Investigate physcal principles involved
Identify conditions producing the problem
Consider production inputs
Determine optimal conditions
Investigate measurement methods
Identify deficiencies
Formulate and implement improvement plan
7. Failure-Loss Reduction Program

The six zero-breakdown measures:

Eliminate accelarated deterioration by establishing basic equipment conditions (cleaning, lublicating, and tightening
Eliminate accelarated deterioration by complying with conditions of use.
Restore equipment to its optimal condition by restoring deterioration
Restore processes to their optimal condition by abolishing environments that cause accelerated deterioration
Lengthen equipment lifetimes by correcting design weaknesses
Eliminate unexpected failures by improving operating and maintenance
Four phases of zero breakdowns: stabilize failure intervals, lengthen equipment life, periodically resore deterioration, predict equipment life

8. Performance-Loss Improvement Program

Eliminating normal production losses
Reducing abnormal production losses
9. Defect-Loss Reduction Program

10. Process Simplification Program

11. Conclusion – the key to focused improvement is to keep the approach simple. Rather than trying to apply a cocktail of complex theoretical techniques, it is far more effective to adopt the shop-floor approach: first expose and eradicate all minor flaws, restore deterioration, and painstakingly establish basic conditions. More sophisticated improvements become possible only when you solve the basic problems.

to be continued…

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