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عدد المساهمات : 19001 التقييم : 35505 تاريخ التسجيل : 01/07/2009 الدولة : مصر العمل : مدير منتدى هندسة الإنتاج والتصميم الميكانيكى
| موضوع: كتاب Total Productive Maintenance - Strategies and Implementation Guide الجمعة 23 فبراير 2024, 7:31 pm | |
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أخواني في الله أحضرت لكم كتاب Total Productive Maintenance - Strategies and Implementation Guide Tina Kanti Agustiady, Elizabeth A. Cudney
و المحتوى كما يلي :
Contents Preface .xv Acknowledgments . xvii About the Authors xix 1. Introduction .1 Four-Phase Approach 2 TPM Project Backgrounds 6 TPM Case Study Goals 6 Learning Design 7 Conclusion 7 Questions 8 References .8 2. Overview—TPM and How It Fits into Lean, Goals and Benefits of TPM, History, Pillars of TPM .9 History of TPM .9 TPM 11 Goals and Benefits of TPM 12 Pillars of TPM 12 Questions 20 References . 21 3. TPM and Lean .23 Visual Management . 32 Cellular Processing 35 Mapping the Flow 36 Conclusion 37 Questions 37 References .38 4. TPM and Six Sigma 39 Six Sigma .39 Variation 41 Project Charters 43 SIPOC .45 Kano Model 46 CTQ 49 Affinity Diagram .50 Measurement Systems Analysis 50 Gage R&R .50viii Contents Process Capabilities .57 Capable Process (Cp) .57 Capability Index (Cpk) 58 Possible Applications of Process Capability Index 59 Potential Abuse of C p and Cpk 59 Graphical Analysis 63 Cause-and-Effect Diagram .63 Failure Modes and Effects Analysis (FMEA) .66 Hypothesis Testing 68 ANOVA 71 Correlation 72 Simple Linear Regression .72 Correlations: Trial 1, Time 74 Analysis of Variance . 74 Unusual Observations 74 Hypothesis Testing .75 Theory of Constraints .75 Single-Minute Exchange of Dies (SMED) .79 Description of Stage 1—Separate Internal versus External Setups .82 Description of Stage 2—Convert Internal Setups to External Setups 84 Advance Preparation of Conditions 84 Function Standardization .84 Implementing Function Standardization with Two Steps .84 Description of Stage 3—Streamline All Aspects of the Setup Operation 84 Ask Questions Such As 84 Improving Storage and Transport 85 Streamlining Internal Setup 86 Implementing Parallel Operations .86 Conclusion 86 Questions 88 References .89 5. Overview—Types of Maintenance . 91 Types of Maintenance Involved with TPM 91 Breakdown Maintenance 93 Preventive Maintenance .95 Predictive Maintenance 98 Corrective Maintenance 99 Quality Function Deployment 102 Design of Experiments . 102 Full Factorial . 104 Fractional Factorial . 105 Maintenance Prevention . 107Contents ix Questions 109 References . 109 6. Equipment Effectiveness 111 Overall Equipment Effectiveness 111 Planned versus Total Maintenance . 116 Maintainability . 116 Reliability 117 Equipment FMEA 118 Conclusion 122 Questions 122 References .122 7. Introducing and Institutionalizing TPM 123 Introducing TPM 123 Deploying TPM . 124 Institutionalizing TPM . 126 Questions 133 References . 133 8. Preparatory and Introduction Stages . 135 Preparatory Stage . 135 Introduction Stage . 139 Conclusion 141 Questions 141 References . 145 9. TPM Pillars 147 Pillar 1: 5S 147 Pillar 2: Autonomous Maintenance (Jishu Hozen) 150 Pillar 3: Kobetsu Kaizen (Particular Case) . 153 Pillar 4: Planned Maintenance . 154 Pillar 5: Quality Maintenance 156 Pillar 6: Training 157 Pillar 7: Office TPM 160 Pillar 8: Safety, Health, and Environment 160 Common Targets for Lean, Six Sigma, and TPM 162 Benefits for Lean, Six Sigma, and TPM . 162 Questions 164 References . 164 10. Hoshin Kanri . 165 Hoshin Kanri Overview . 165 Organizational Culture . 167x Contents Two Levels of Policy Deployment . 167 Planning for Policy Deployment . 168 Daily Management of Policy Deployment 168 Develop a Hoshin Strategic Plan Summary 172 How to Create a Hoshin Strategic Plan Summary for Your Organization 173 Drive Your Strategy Down to the Department Level—Develop a Hoshin Plan Summary 175 Develop Implementation Strategies for Your Hoshin Plan Summary 176 Decide Where You Want to Focus Your Improvement Efforts . 177 Develop Your Hoshin Action Plan 177 Develop Your Hoshin Implementation Plan 179 Conduct a Hoshin Implementation Review . 180 The Three Main Tools of Policy Deployment 183 Deming’s Plan–Do–Check–Act Cycle 183 Cross-Functional Management . 184 Catchball . 184 Conclusion 184 Questions 185 References . 186 11. Organizational Change Management 187 Organizational Change Management 187 Resistance to the Status Quo 193 Utilizing Known Leaders to Challenge the Status Quo . 194 Communicating Change . 194 Questions 198 References . 199 12. TPM Case Study: Hydraulic Leak Reduction . 201 Chad Olson, Xueyang Chen, Heng Liu, and Elizabeth Cudney Introduction 201 Define . 202 Measure . 202 Analyze .204 Design 207 Verify .208 Improve .208 System Improvements 208 Control . 210 Financial Savings . 211 Conclusions . 211 References . 211Contents xi 13. TPM Case Study: Pressure Regulator 213 Bill Dean, Charlie Barclay, Nanda Dey, and Elizabeth Cudney Executive Summary . 213 Define . 213 Problem Statement 213 Problem Goals . 215 Requirements and Expectations . 215 Project Boundaries 215 Process Flow Diagram 215 Measure . 215 Gage Repeatability and Reliability . 216 Data Collection 219 Process Baseline 220 Graphical Analysis 220 Analyze .222 Current Gaps between Performance and Customer Expectations .222 Failure Modes and Effects Analysis .222 Sources of Variation 222 Prioritization of Improvement Opportunities 227 Hypothesis Testing .227 Improve . 231 Identification of Solutions 231 Control . 231 Financial Savings . 231 Conclusions . 231 References . 232 14. TPM Case Study: Roller Assembly Redesign .233 DeVaughan Woodside, Apurva Chinchore, Sujitkumar Dongare, and Elizabeth Cudney Introduction 233 Design for Six Sigma (DFSS) 233 Project Description 233 Project Goals 236 Requirements and Expectations .236 Project Boundaries 238 Project Management 238 I2DOV Road Map .238 Gantt Chart 241 Invent/Innovate . 241 SWOT Analysis (VOC) . 241 Critical to Satisfaction . 245 Data Collection Plan . 245 Quality Function Deployment/House of Quality . 247xii Contents Design 248 Concept Generation (3P) .250 Seven Concepts 251 Pugh’s Concept Selection . 251 Prototype Selected/Final Design 254 Optimize .255 Design Failure Modes and Effects Analysis .255 Validate 256 Process at a Glance 256 Trial Runs . 257 Financial Savings 259 Conclusion 260 References .266 15. TPM Case Study: Sticky Foil . 267 Adebolaji Jobi-Taiwo, Adam Miller, Amelia Lopez, and Elizabeth Cudney Introduction 267 Project Charter and Project Management Plan Highlights . 267 Project Charter . 267 Project Management Plan 268 Define .268 Problem Statement 270 Problem Goals . 270 Requirements and Expectations . 271 Project Boundaries 271 Process Flow Diagram 271 Measure . 274 Data Collection 274 Process Baseline 274 Process Data . 274 Analyze . 279 Current Performance and Customer Expectations 279 Sources of Variation 280 Gap Analysis 280 Improve .280 Possible Causes Ruled Out 281 Potential Causes to Analyze Further .283 Control .284 Financial Savings .284 Conclusions .284 References .286Contents xiii 16. Future and Challenges of TPM . 287 TPM in Service and Healthcare . 287 Applying TPM Concepts to the Design and Development Life Cycle .288 Engagement and Success Factors .290 References . 292
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