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Inhaltsangabe:Abstract: Modern manufacturing requires that organisations that want to be successful and to achieve world-class manufacturing must posses both effective and efficient maintenance. One approach to improve the performance of maintenance activities is to implement a Total Productive Maintenance (TPM) system. The aim of this dissertation is to prove that the introduction of a TPM system is by no means an easy task, because there are several barriers that encumber the implementation process, the driving forces to success have to be identified and well understood, and a process of organisational change has to be managed successfully. The study analyses impediments, barriers and obstacles to the implementation procedure and discovers key success factors concluding with a conceptual framework for a successful TPM implementation. The dissertation also examines the challenge of managing change within the TPM context and identifies that such a TPM journey requires employee and management commitment to be successful. Through a case study of implementing TPM in an automotive supplier company, the practical aspect within and beyond basic TPM theory and problems encountered during the implementation are discussed and analysed. The paper concludes that the implementation of TPM is definitely not an easy task, which is considerably burdened by organisational, behavioural and other barriers, and necessitates the difficult mission to change peoples mindsets from a traditional maintenance approach. Inhaltsverzeichnis:Inhaltsverzeichnis: Title page01 Declaration and Word Count02 Abstract03 Acknowledgements04 Table of contents05 List of figures09 CHAPTER 1INTRODUCTION10 1.1Importance of TPM10 1.2Problem statement and objectives11 1.3Research methods12 1.4Structure of the study13 CHAPTER 2LITERATURE REVIEW14 2.1Defining TPM14 2.2Basic concept14 2.3Performance measurement17 2.4New roles of operators and maintenance staff19 2.5The JIPM s 12 steps to implement TPM21 2.6The connection between TPM and TQM23 2.7TPM in the view of change25 CHAPTER 3METHODOLOGY29 3.1Company profile and TPM background29 3.1.1General information about the company29 3.1.2CME: The plant of the focus of this study30 3.2Explanation, justification and limitations of selected methods32 3.2.1Focus group discussion32 3.2.1.1Data collection procedure33 3.2.1.2Data evaluation34 3.2.2Participant observation35 3.2.3Document analysis36 CHAPTER 4FINDINGS [...]
To be able to compete successfully both at national and international levels, production systems and equipment must perform at levels not even thinkable a decade ago. Requirements for increased product quality, reduced throughput time and enhanced operating effectiveness within a rapidly changing customer demand environment continue to demand a high maintenance performance. In some cases, maintenance is required to increase operational effectiveness and revenues and customer satisfaction while reducing capital, operating and support costs. This may be the largest challenge facing production enterprises these days. For this, maintenance strategy is required to be aligned with the production logistics and also to keep updated with the current best practices. Maintenance has become a multidisciplinary activity and one may come across situations in which maintenance is the responsibility of people whose training is not engineering. This handbook aims to assist at different levels of understanding whether the manager is an engineer, a production manager, an experienced maintenance practitioner or a beginner. Topics selected to be included in this handbook cover a wide range of issues in the area of maintenance management and engineering to cater for all those interested in maintenance whether practitioners or researchers. This handbook is divided into 6 parts and contains 26 chapters covering a wide range of topics related to maintenance management and engineering.
Reduce or eliminate costly downtime Short on teory and long on practice, this book provides examples and case studies, designed to provide maintenance engineers and supervisors with a framework for operational strategies and day-to-day management and training techniques that will keep their equipment running at top efficiency.
Productivity and Reliability-Based Maintenance Management, Second Edition is intended to provide a strong yet practical foundation for understanding the concepts and practices of total productive maintenance (TPM) management—a proactive asset and resource management strategy that is based on enhancing equipment reliability and overall enterprise productivity. The book is intended to serve as a fundamental yet comprehensive educational and practical guide for departing from the wait-failure-emergency repair cycle that has plagued too many industries, instead advancing a proactive and productive maintenance strategy. It is not intended to be a how-to-fix-it manual, but rather emphasizes the concept of a world-class maintenance management philosophy to avoid the failure in the first place. Universities, junior and community colleges, and technical institutes as well as professional, corporate, and industrial training programs can benefit by incorporating these fundamental concepts in their technical and managerial curricula. The book can serve as a powerful educational tool for students as well as for maintenance professionals and managers. In addition to updating the previous historical and statistical data and tables, the second edition expands on and adds to case studies based on current maintenance-related events. Several numerical examples and explanations are revised in order to enhance the clarity of the methodology. The second edition introduces the readers to the state-of-the-art concepts of the Internet of Things (IoT), smart sensors, and their application to maintenance and TPM.
This book present the state of the art in Total Productive Maintainance (TPM) and its benefits. The authors present a survey applied to 368 manufacturing industries in order to determine their level of execution of TPM. Then a series of causal models are presented. For each model, the authors present a measure of the dependency between the critical success factors and the benefits obtained, allowing industry managers to differentiate between essential and non-essential activities. The content also allows students and academics to obtain a theoretical and empirical basis on the importance of TPM as a lean manufacturing tool in the context of industry 4.0.
Process industries have a particularly urgent need for collaborative equipment management systems, but until now have lacked for programs directed toward their specific needs. TPM in Process lndustries brings together top consultants from the Japan Institute of Plant Maintenance to modify the original TPM Development Program. In this volume, they demonstrate how to analyze process environments and equipment issues including process loss structure and calculation, autonomous maintenance, equipment and process improvement, and quality maintenance. For all organizations managing large equipment, facing low operator/machine ratios, or implementing extensive improvement, this text is an invaluable resource.
TPM for Every Operator covers the information that needs to be communicated to operators when facilitating a company-wide TPM initiative. It covers the main aspects of TPM, introducing frontline workers to this important manufacturing strategy that encourages them to participate in and even initiate routine maintenance that can help extend machine life and prevent stoppages. Based on actual implementations, this book addresses the challenges which TPM often raises for operators. Concise and accessible, it can be used as part of an extensive TPM training program, especially when paired with the TPM Guide for Workshop Leaders.
In order to achieve zero-defect product quality, a company needs to trace defects in equipment to their root causes and permanently eliminate them. Learn how to integrate TPM concepts and methods in your quality program in this easy-to-read case study of TPM, TQC, and JIT at a world-class manufacturer of optical fiber and other electric cable and wire. Using numerous shop floor examples, the author shows supervisors and team leaders how to manage equipment to guarantee higher quality. Contents Publisher's Message Foreword to the Japanese Edition Preface 1. The Zero Defect Challenge 2. TPM Development at Furukawa Electric 3. Deploying the Five S's and Autonomous Quality Maintenance 4. The Mechanism Behind Failures and Defects 5. The Basic Approach to Defect Prevention 6. Deploying MQP Management 7. Planned Quality Maintenance 8. TPM and the JIT Production System 9. Improvement Results and Future Topics About the Author Index
This second edition of An Introduction to Predictive Maintenance helps plant, process, maintenance and reliability managers and engineers to develop and implement a comprehensive maintenance management program, providing proven strategies for regularly monitoring critical process equipment and systems, predicting machine failures, and scheduling maintenance accordingly. Since the publication of the first edition in 1990, there have been many changes in both technology and methodology, including financial implications, the role of a maintenance organization, predictive maintenance techniques, various analyses, and maintenance of the program itself. This revision includes a complete update of the applicable chapters from the first edition as well as six additional chapters outlining the most recent information available. Having already been implemented and maintained successfully in hundreds of manufacturing and process plants worldwide, the practices detailed in this second edition of An Introduction to Predictive Maintenance will save plants and corporations, as well as U.S. industry as a whole, billions of dollars by minimizing unexpected equipment failures and its resultant high maintenance cost while increasing productivity. - A comprehensive introduction to a system of monitoring critical industrial equipment - Optimize the availability of process machinery and greatly reduce the cost of maintenance - Provides the means to improve product quality, productivity and profitability of manufacturing and production plants