Autonomous Maintenance is geared towards developing operators to be able to take care of small maintenance tasks, thus freeing up the skilled maintenance people to spend time on more value added activities and technical repairs. The operators are responsible for upkeep of their equipments to prevent it from deteriorating. The main aim is to create uninterrupted operation of equipments, flexible operators to operate and maintain other equipments, eliminating the defects at source through active employee participation and stepwise implementation of JH activities.
Kobetsu Kaizen primarily focuses around Performance efficiency related losses. All the losses which occure during production are captured here and based on that details Production Downtime reports are generated. Several other complex calculations like OEE (Overall Equipment Efficiency) & OPE (Overall Plant Efficiency) are calculated in this pillar.
The goal of Planned Maintenance is to have trouble free machines and equipment that produce defect free products for total customer satisfaction. It captures the breakdown details and the maintenance details. The main functionality provided by this pillar is to calculate the production stoppage time, keep track of failed equipments and loss phenomena. User can get the breakdown reports, schedule a PM activity for any date period, and specify the consumable parts which are required. Major trends like MTTR and MTBF, total cost for all maintenance activities can also be obtained.
Quality Maintenance targets customer satisfaction through defect free manufacturing of highest quality products. The main activities are to set equipment conditions that preclude quality defects, based on the basic concept of maintaining perfect equipment to maintain perfect quality of products. The conditions are checked and measure in time series to verify that measured values are within standard values to prevent defects. It also supports Quality Assurance through defect free conditions and control of equipments and segregation of defects at the source.
Education & Training
The goal of Education & Training is to have multi-skilled employees whose morale is high and who are eager to come and perform all required functions effectively and independently. It is necessary for Operators to continuously upgrade their skills through regular education and training. They must know how to carry out the process correctly. Evaluations can be done on employees skills and report for the same is also obtained. User can also analyze the improvement of an employee skill before and after training.
Safety, Health & Environment
This focus to create a safer workplace and surrounding areas that are not damaged by our process or procedures and also to reduce accidents, fires and health damage. All the incidents are reported in this module and each record is classified under the category whether it is a Near miss, accident or injury. Report for the same can also be obtained.
Early Management deals with improving the design of new equipments. Current machine (information leading to failure prevention, easier maintenance, prevention of defects, safety and ease of manufacturing) are studied and changes related to designs, costs are incorporated in new equipment.
Office TPM helps to improve productivity, efficiency in the administrative functions, and eliminate losses. This includes analyzing processes and procedures towards increased office automation. The process reduces the expenses, communication time and time spent on retrieval of information.
5S Philosophy focuses on effective work place organization, simplifies work environment, reduces waste while improving quality and safety.There is no hope for efficiency or quality improvement with waste of time and scrap. Auditors enter the individual 5S scores for a particular task and check the result with the decided benchmarks.
b) Why Why Analysis:
It is a method of questioning that leads to the identification of the root cause(s) of a problem. A why-why is conducted to identify solutions to a problem that address it’s root cause(s). Rather than taking actions that are merely band-aids, a why-why helps you identify how to really prevent the issue from happening again.
Kaizen is small improvements and a change for better. A kaizen is a small improvement without much data analysis. It must be accompanied by change of method. The Kaizen concept stimulates productivity improvement as an ongoing process in any company. It is a practice oriented strategy which leads to creation of culture of improvement. It is more a way of life or at least a cultural approach to quality improvement. The implementation of philosophy of Kaizen can be achieved through involvement of employees to effect improvements.
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