![]() ![]() TPM blurs the distinction between maintenance and production by placing a strong emphasis on empowering operators to help maintain their equipment. Total Productive Maintenance is a holistic approach to maintenance that focuses on proactive and preventative maintenance to maximize the operational time of equipment. It is calculated as Planned Production Time / Customer Demand. Takt Time is the pace of production (e.g., manufacturing one piece every 34 seconds) that aligns production with customer demand. It must be “living” documentation that is easy to change. Standardized Work is documented procedures for manufacturing that capture best practices (including the time to complete each task). SMART Goals are goals that are: Specific, Measurable, Attainable, Relevant, and Time-Specific. Six Big Losses are six categories of productivity loss that are almost universally experienced in manufacturing: Simplify internal setup (e.g., replace bolts with knobs and levers).Convert setup steps to be external (performed while the process is running). ![]() Single Minute Exchange of Die reduces setup (changeover) time to less than 10 minutes. A common approach is to ask why five times – each time moving a step closer to discovering the true underlying problem. ![]() Root Cause Analysis is a problem solving methodology that focuses on resolving the underlying problem instead of applying quick fixes that only treat immediate symptoms of the problem. Poka-Yoke is desiging error detection and prevention into production processes with the goal of achieving zero defects.
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