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Japan Institute of Plant Maintenance, Ed.

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Chapter Synopses: Our TPM, Using Machines Efficiently, Eliminating Breakdowns, Autonomous Maintenance, Team Activities, TPM and Safety A simple very effective way to immerse every frontline worker in Total Productive Maintenance.

Total employee involvement is the foundation of any successful TPM program. To improve production quality and lower costs, the education and participation of all employees is essential. TPM for Every Operator introduces frontline workers to the basics of TPM, concentrating on focused improvement, autonomous maintenance, and safety activities. The explicit illustrations that appear on almost every page visually reinforce such TPM principles as: •  eliminating the six big losses that cause breakdowns and defects •  establishing a daily cleaning, lubrication, and bolt tightening routine •  working with maintenance personnel to improve equipment effectiveness •  promoting equipment improvement through independent small group activities.

TPM for Every Operator is part of the Productivity Press Shopfloor Series, condensed books for operators, team leaders, and supervisors containing information on key manufacturing topics. This book is a companion volume to TPM Team Guide which discusses the principles of team-based TPM activities. We express our appreciation to the Japan Institute of Plant Maintenance, the original author and publisher, for permitting us to publish this edition of TPM for Every Operator.

About the Editor:The Japan Institute of Plant Maintenance is a nonprofit research, consulting, and educational organization that helps companies increase organizational efficiency and profitability through improved maintenance of manufacturing equipment, processes, and facilities. Based in Japan, JIPM is the innovator of methodologies that have been implemented around the world. We are pleased to publish many English editions of their groundbreaking publications.


Chapter 1: Our TPMDefines TPM and its five major components. Operators play a crucial role in the preventive maintenance, otherwise known as "avoiding equipment breakdown." This chapter introduces the goals and key strategies of TPM, and explains why you need TPM the most when you are at your busiest. •  From PM to TPM •  Productive Maintenance•  Preventive Maintenance•  Corrective Maintenance•  Maintenance Prevention•  Breakdown Maintenance•  What Kind of Workplace Suffers from Defects and Equipment•  Breakdowns?•  Preventive Maintenance Is Health Management for Machines•  A Definition of TPM•  Why Do TPM?•  What Makes TPM Different? •  The Goals of TPM•  The Eight Key Strategies of TPM Development•  Six Big Losses That Lower Equipment Efficiency •  The Busier You Are, the More You Need TPM •  Summary

Contributor: Akira Ichikawa, TPM Operations Consultant, JIPM

Chapter 2: Using Machines Efficiently.The result of TPM should be to increase overall equipment effectiveness, OEE. OEE goes up when you eliminate the 6 big losses: breakdowns, setup loss, minor stoppages, reduced speed, defects and rework, and startup and yield loss. Operators can play a major role in eliminating these six losses simply by questioning small annoyances, especially these annoyances, before they become big problems. Asking why several times uncovers the root causes of problems. This chapter tells you how to ask the right questions to get the right answers. •  What Are the Six Big Losses? •  You Can't Make Products When Your Equipment Breaks Down•  Setups Take Too Long•  The Smallest Thing Can Shut Down a Machine •  Running Equipment Faster Causes Defects •  Are You Making Defective Products? •  It Takes Time to Get Started in the Morning •  OEE: an Indicator of Equipment Health •  Which Loss Is the Worst Offender? •  A Phrase That Invites Losses: This Isn't Too Bad •  Eradicating Minor Defects Yields Big Profits •  Improvement Begins with Restoration •  Grit and Dust Shorten Equipment Life •  Losses Vanish in Workplaces Where People Ask Why? •  Take Care of Your Own Equipment •  Summary

Contributor: Kazumi Takagi, TPM Operations Consultant, JIPM

Chapter 3: Eliminating BreakdownsThe majority of breakdowns are preventable. Accelerated deterioration shortens equipment life but can be avoided through preventive maintenance. The principles of preventive maintenance are introduced, with useful pointers on how to prevent equipment breakdown.•  Breakdowns Come in Two Types •  Breakdowns Are Caused by People •  Why Do Machines Fail?•  When Do Breakdowns Happen? •  Two Types of Deterioration •  The Buck Stops Here•  Watch for Slight Abnormalities •  Coming to Grips with Zero Breakdowns •  Providing the Basics (Cleaning and Inspecting, Lubricating, and Tightening)•  Daily Checks Are the First Step of PM •  Find the Root Cause and Restore the Equipment •  Nip Breakdowns in the Bud with Autonomous Maintenance•  Why General Inspection? •  Learning How Not to Break Equipment •  Learning from Breakdowns •  Summary

Contributor: Yuzo Takebe, TPM Operations Consultant, JIPM

Chapter 4: Autonomous Maintenance Describes this operator-based program which is implemented in seven steps. This chapter also explains tagging--problem spots are tagged for immediate visibility, then the tags are systematically removed after the root cause of the problem has been eliminated. Among other explanations, this chapter tells you how to implement this excellent method of maintenance. •  What Is Autonomous Maintenance? •  Autonomous Maintenance Step by Step •  Step 1: Clean and Inspect •  Step 2: Eliminate Problem Sources and Inaccessible Areas•  Step 3: Draw up Cleaning and Lubrication Standards•  Step 4: Conduct General Inspections •  Step 5: Conduct Autonomous Inspections •  Steps 6 and 7: Sustain Your Gains and Continue to Improve•  Why Autonomous Maintenance? •  Step Audits Are for Training and Mutual Learning•  Tags Are Bandages for Machines •  Autonomous Maintenance Is a Daily Workout for Equipment•  Who Benefits from Autonomous Maintenance? •  Summary

Contributor: Kazuhisa Yamazaki, TPM Operations Consultant, JIPM

Chapter 5: Team ActivitiesTeaches basic points of TPM team activities: selecting leaders, setting team goals, learning from management audits, and publicizing results. It introduces the three secret weapons for battling loss: activity boards, team meetings, and one-point lessons.•  What Are TPM Team Activities? •  What Is the Goal of Team Activities? •  Selecting Leaders •  The Team Leader: a Crucial Role •  Team Members Are Important, Too •  How to Choose a Project •  Set Firm Objectives•  Involve Management in Auditing Team Activities •  Three Secret Weapons for Teams •  Using Activity Boards Effectively •  How to Hold Productive Meetings •  Using One-Point Lessons •  Publicize Results•  Summary Contributor: Takao Izumi, TPM Operations Consultant, JIPM

Chapter 6: TPM and SafetyClarifies how to improve safety on the job. Basic TPM activities such as cleaning and inspection make it harder for difficulty, dirt, and danger to find their way into the workplace. Autonomous maintenance activities systematically eliminate the minor problems and unsafe conditions that turn into breakdowns and accidents. Awareness training and coordinated teamwork help employees recognize and avoid unsafe behaviors. The text is followed by a brief list of books for further reading on TPM and related subjects. •  Safety Is the Cornerstone of Production A•  Drive the "Three Evils" out of the Workplace •  Why Do Accidents Happen? •  The Pyramid of Accident Causes •  Three Safety Principles •  Develop Safety Together with Autonomous Maintenance •  Safety Activities Should Be Continual and Progressive•  Making Safety Checks•  Making Maintenance Activities Safer •  Standardizing Operations •  Checkpoints for Nonrepetitive Activities •  Hazard Awareness Training •  Active Signaling •  Three Secret Weapons for Safety Awareness •  Draw up a Safety Promotion Plan •  Summary

Contributor: Shinichi Shinozuka, TPM Operations Consultant, JIPM

Praise for TPM For Every Operator

"Our TPM implementation team has been looking for an operator friendly TPM manual that is easily understood and can be used by that area team as a reference as they become increasingly effective in their operation. We plan to use TPM for Every Operator as that Manual."Noel LasureMaster Facilitator, Stemco

"TPM for Every Operator is going to be a definite asset to our organization's total productive maintenance program. The clear presentation or the concept set this book apart from many of the others I have read. Since beginning our program in April 1995, I have had great difficulty finding information about TPM that not only complemented various skill levels but also various learning styles. TPM for Every Operator has done this. I feel confident that this book is going to become an integral part of our TPM training sessions and small group activities. I am very impressed to say the least." - Valerie Shelton TPM Coordinator, Teksid Aluminum Foundry Inc., A Division of Fiat S.p.A.

"The training manual, TPM for every Operator, represents a tremendous tool to focus group activities and awareness on a decentralized maintenance program. The definitions of the Eight Key Strategies and the Six Machine Losses are easy to depicting a situation that really relates to the reader. TPM for Every Operators.Leaves the operator with a vision and philosophical view of where this information will take them. I believe it rates a graduated Thumbs Up on all aspects. D. Michael LoveProduction Manager, Boise Cascade Corrugated

137 pages, cartoons, charts, 1996

ISBN No/Item Code: 9781563270802

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