Lean manufacturing cannot happen in a factory that lacks dependable, effective equipment. Breakdowns and processing defects translate into excess work-in-process and finished inventory, kept on hand ""just in case."" Recurring minor stoppages force employees to watch automated equipment that should run by itself. TPM gives a framework for addressing such problems, but many companies implement TPM at a superficial level, and the resulting productivity gains fall short of their potential. If your TPM implementation has resulted in posters and logos rather than a rise of productivity, how are you addressing this halt of progress? In TPM for the Lean Factory, authors Sekine and Arai teach you to identify and attack the key equipment-related problems and misunderstandings that make plants miss their lean manufacturing goals.

Written for companies with a basic TPM framework already in place, you'll learn three powerful approaches for cutting this waste:

  • The new 5Ss: focusing on standard locations and labeling through the first 2Ss
  • Instant maintenance: mastering quick repairs of minor equipment failures
  • Improved setup operations: organizing the preparation to save time and prevent errors

Chapters on cell design, product and process quality factor testing, and daily equipment inspection give you additional weapons for fighting waste and low productivity. For practical application, an implementation overview summarizes the steps for each topic, keyed to a set of 50 adaptable worksheets and examples. A practical and supportive resource, TPM for the Lean Factory extends a fresh vision and focus to help you get top results from your TPM efforts.

part I

TPM for the Lean Factory

chapter 1|11 pages

The Seven Types of Waste in TPM

chapter 2|12 pages

The 5Ss Begin with the 2Ss

chapter 3|23 pages

A New 5S Example: Mynac Company Case Study

chapter 4|16 pages

The Fundamentals of Instant Maintenance

chapter 5|20 pages

A Case Study in Instant Maintenance

chapter 6|18 pages

Improving Setup Operations

chapter 7|16 pages

Eliminating the Waste of Planned Downtime

chapter 9|33 pages

Promoting Daily Equipment Inspections

chapter 10|24 pages

Test Yourself: A Lean TPM Quiz

chapter 11|14 pages

Implementation Overview for TPM Innovation

chapter 12|111 pages

Worksheets for TPM Innovation