TPM in Process Industries

TPM in Process Industries PDF Book Detail Author: Tokutaro Suzuki
Publisher: CRC Press
ISBN: 9781563270369
Category : Business & Economics
Languages : en
Pages : 424

Book Description
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 in Process Industries

TPM in Process Industries PDF Book Detail Author: Tokutaro Suzuki
Publisher: Routledge
ISBN: 1351407422
Category : Business & Economics
Languages : en
Pages : 416

Book Description
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.

Implementing TPM

Implementing TPM PDF Book Detail Author: Andrew Ginder
Publisher: CRC Press
ISBN: 1000123375
Category : Business & Economics
Languages : en
Pages : 224

Book Description
This book provides an understanding of the complexity and comprehensiveness of the total productive maintenance (TPM) process. It supplements works by Japanese authors with guidance and detail on how the TPM process relates to North American plants or facilities.

Lean for the Process Industries

Lean for the Process Industries PDF Book Detail Author: Peter L. King
Publisher: CRC Press
ISBN: 0429681720
Category : Business & Economics
Languages : en
Pages : 260

Book Description
Compared to its widespread implementation across almost all areas of production, Lean improvement efforts lag within the process industries. While many innovators have successfully applied Lean principles to these industries during the past three decades, most of those pioneering efforts were never recorded to guide the improvement efforts of others. Drawing on more than 40 years of application experience at one of the world’s largest chemical and materials manufacturers, coupled with 10 years in private practice, Peter King corrects this void by providing the first comprehensive resource written explicitly for change agents within the process industries. Focusing on areas where the improvement needs of the process industry differ from parts assembly manufacturing, Lean for the Process Industries: Dealing with Complexity, Second Edition: Covers each of the eight wastes commonly described in Lean literature, looking at how they manifest themselves in process operations. Explains how to adapt value stream mapping for process operations. Shows how to identify the root causes of bottlenecks, and how to manage them to optimize flow until they can be eliminated. Provides practical techniques to overcome the barriers which have prevented the application of Cellular Manufacturing to process operations. Discusses the role of business leadership in a Lean strategy, describing both enabling and counter-productive management behaviors Since the publication of the first edition of this book, Peter King has been busy consulting with food, beverage, gasoline additive, and nutraceutical companies -- these new experiences have broadened his perspectives on certain Lean processes and have given him a richer set of examples to discuss in this new edition. While Value Stream Mapping is a very powerful tool to understand flow, bottlenecks, and waste in an operation, the traditional format as presented in many other books does not describe all of the data required to fully understand process flow and its detractors. This new edition highlights the necessary additions with examples of why they are useful. Product wheel scheduling achieves production leveling in a far more comprehensive and effective way than traditional heijunka methods. This edition has a more thorough description of the wheel concept and design steps, and more examples from actual applications.

TPM for the Lean Factory

TPM for the Lean Factory PDF Book Detail Author: Keisuke Arai
Publisher: CRC Press
ISBN: 9781563271915
Category : Business & Economics
Languages : en
Pages : 416

Book Description
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.

Non Stock Production

Non Stock Production PDF Book Detail Author: Shigeo Shingo
Publisher: CRC Press
ISBN: 9780915299300
Category : Business & Economics
Languages : en
Pages : 498

Book Description
Shingo, whose work at Toyota provided the foundation for JIT, teaches how to implement non-stock production in your JIT manufacturing operations. The culmination of his extensive writings on efficient production management and continuous improvement, this book is an essential companion volume to his other landmark books on key elements of JIT, including SMED and poka-yoke. It includes: Fundamental flaws in European and American production philosophies. Basic concepts for improving production systems. The "scientific thinking mechanism" -- a new approach to improvement. Implementing a production method in an age of authorized stock production. Development of production functions in the age of non-stock production. Significance of the different production systems.

Kanban Just in Time at Toyota

Kanban Just in Time at Toyota PDF Book Detail Author: Japan Management Association
Publisher: CRC Press
ISBN: 9780915299485
Category : Business & Economics
Languages : en
Pages : 228

Book Description
Toyota's world-renowned success proves that just-in-time (JIT) makes other manufacturing practices obsolete. This simple but powerful book is based on the seminars given by Taiichi Ohno and other senior production staff to introduce Toyota's own supplier companies to JIT. It teaches the philosophy and implementation of what many call the most efficient production system in the world. Provides a clear structure for an introductory JIT training program. Explains every aspect of the JIT system, including how to set it up and how to refine it once it's in place. Shows how to use a simple visual system to control the production process. Every day more American companies are learning that JIT works outside Japan. Now you can get started with this step-by-step book which guides you through the implementation process. Every engineer, manager, supervisor, and worker should read this book to get the clearest, simplest, and most complete introduction to JIT available in English. Results at American companies after reading this book: Lead-time on one product was reduced from 12 weeks to 4 days. Setup time on a large blanking press was reduced from eight hours to one minute and four seconds. Work-in-process has been reduced 50 percent plant-wide. Factory floor space was opened up 30 to 40 percent in every on of their plants.

LEAN MANAGEMENT THE LAUNCHPAD FOR GLOBALIZATION INDUSTRIAL REVOLUTION AND IMPOWERMENT

LEAN MANAGEMENT  THE LAUNCHPAD FOR GLOBALIZATION  INDUSTRIAL REVOLUTION AND IMPOWERMENT PDF Book Detail Author: Dr. Suresh Sharma
Publisher: Horizon Books ( A Division of Ignited Minds Edutech P Ltd)
ISBN: 8194823188
Category : Business & Economics
Languages : en
Pages : 272

Book Description
Lean Manufacturing concept has brought new industrial revolution and the battle lines are clearly drawn. It is traditional mass production versus the trim and tidy lean Enterprising. Lean experts and past researchers plead; Lean production is a superior way for humans to make things. It provides better products in wider variety at lower cost. It provides more challenging and fulfilling work for employees at every level. The whole world should adopt lean production, and as quickly as possible. Henry Ford defined Lean Enterprising stating, “If it does not add value, it is waste”. This concept was later adopted by Toyota as the core idea behind the famous Toyota Production System (T.P.S). The Toyota Production System is the foundation of many books on “lean”. It is the story of Lean Production how Japan’s secret weapons in the global auto wars later revolutionized western industries. The concept of lean manufacturing was widely accepted. A Standard S.A.E J 4000:1999 was also released to specify Lean in detail. The purpose of this book is to share the knowledge and experience gained through collaborative contribution - with a wide range of readers including; students, managers, entrepreneurs, industrial leaders, university professors, and self-learning professionals. Implementation of lean practices mainly in automobile and engineering industries provide valuable insight. Further, the book describes how it can be applied to wider field of work including; shipbuilding, information technology, environmental protection, transportation services and performance management from human resource perspective. My presentations on LEAN in conferences and published papers in international journals like; Elsevier, IEEE, and David Publishing-USA are also included to provide valuable inputs. This book recommends the solution for immediate problems faced by industries and service sectors using lean principles and practices. The generic but common and critical problems that are discussed in depth include; economic crisis, global competition, scarce resources, quality issues, waste generation, volatile market, global warming, and poor performance. These issues have also been examined by the author in his other book, “Management Paradox: Re-examined” as source of tension, dilemma and contradiction. Relevant tools and techniques that are addressed and applied include; Kaizen, Five ‘S’, Visual Management, Just in Time, Kanban System, One Piece Flow, Single Minute Exchange of Die, Total Productive Maintenance and Poka Yoke. For a specific reason mistake-proofing (Poka Yoke) has been elaborated in detail for exploring its effectiveness to add value in product and services. This powerful lean tool took a long time to acquire its place in the list of popular tools because it challenged the effectiveness of statistical process control towards achieving zero-defect. The quantitative and qualitative approaches that have been selected and used based on the field of work and situation will be found interesting by research scholars. Methods like correlation analysis, test of hypothesis, and analysis of variance (ANOVA) have been carried out using the quantitative technique. Qualitative approach has been used for lean and sustainable transport system to understand people’s belief, perspective and experience. This approach supported in handling the important issues of consent and confidentiality. The book also presents the arguments on potential limitations of the lean manufacturing strategy on one hand and criticism on drifting definition of lean on other hand. The book firmly suggests instant applicability of lean principles and practices in sectors like manufacturing and construction. The way to apply lean in other sectors including ICT in conjunction with present practices like; agile for knowledge to apply tools, scrum for experience-based self-direction etc. are recommended. These sector- specific practices are supported by lean principles but the book discovers that exclusively focusing on software development without considering upstream and downstream operations severely limit the benefits. Therefore lean principles support agile and scrum and take much beyond software development. The ideas and recommendations offered in this book can be used for further implementation of lean in a large number of organizations and different fields including MSME, service-providing industries, healthcare, construction management, management education, and for army reforms. A leaner, modern military is the need of the hour.

The Hunters and the Hunted

The Hunters and the Hunted PDF Book Detail Author: James B. Swartz
Publisher: CRC Press
ISBN: 9781563270437
Category : Business & Economics
Languages : en
Pages : 584

Book Description
As a manager who wants to attain, maintain, or reclaim a competitive position in the hotly contested and ever-changing marketplace, your goal is clear. Terrified of being the "hunted" -- in peril of being destroyed or devoured by your competitors you want to know how to once again become a "hunter." But the myriad improvement strategies that sound great in theory don't always work in practice, and they don't take into account the realities of your workplace. Through an unusual and provocative blend of fact and fiction, Jim Swartz puts you inside the transformation process itself - inside the heads of those who, finding themselves among the hunted, realize they must change the fundamental way they do business. He makes it clear why reorganization, decentralization, de-layering, continuous improvement, benchmarking, and participative management are helpful tools but fall short of tackling the real enemy. In this engaging business novel, you'll travel with Marcus, the "Master Guardian" who has been helping businesses in trouble for 1400 years, as he trains two guardian recruits: Lou, a tough steel company manager long on experience with the old ways, and Laura, a Harvard MBA with a global view and no industrial experience. Come along as they visit great business hunters past and present and become aware of the fatal corporate mindsets, mental models, and measures that doom many companies to a life of retreat and restructuring. By visiting turnaround companies, you'll learn new business process models that dramatically reduced costs, improved performance and product quality, and made these companies the fastest responding suppliers in the world.

The Visual Factory

The Visual Factory PDF Book Detail Author: Michel Greif
Publisher: CRC Press
ISBN: 9780915299676
Category : Business & Economics
Languages : en
Pages : 324

Book Description
If you're aware of the tremendous improvements achieved in productivity and quality as a result of employee involvement, then you'll appreciate the great value of creating a visual factory. This book explains why conventional work areas, where fragmented information flows from "top to bottom," must be replaced by the "visual workplace," where information flows in every direction. It details how visual management can make the factory a place where workers and supervisors freely communicate so that every employee can take improvement action. The author's year-long worldwide research resulted in an abundance of practical recommendations. The communication techniques he suggests will: Foster cohesion within groups of employees. Turn fault-based into fact based communication. Overcome such problems as absenteeism and high defect rates. Stimulate an unending flow of suggestions from employees. A valuable resource for plant, operations, and human relations managers, this text discusses how successful companies develop meeting and communication areas, communicate work standard production controls such as kanban, and make goals and progress visible. Over 200 diagrams and photos illustrate the numerous visual techniques discussed.

Advances in Material Science and Engineering

Advances in Material Science and Engineering PDF Book Detail Author: Mokhtar Awang
Publisher: Springer Nature
ISBN: 9811636419
Category : Technology & Engineering
Languages : en
Pages : 413

Book Description
This book presents selected papers from the 6th International Conference on Mechanical, Manufacturing and Plant Engineering (ICMMPE 2020), held virtually via Google Meet. It highlights the latest advances in the emerging area, brings together researchers and professionals in the field and provides a valuable platform for exchanging ideas and fostering collaboration. Joining technologies could be changed to manufacturing technologies. Addressing real-world problems concerning joining technologies that are at the heart of various manufacturing sectors, the respective papers present the outcomes of the latest experimental and numerical work on problems in soldering, arc welding and solid-state joining technologies.

Occupational Safety and Hygiene V

Occupational Safety and Hygiene V PDF Book Detail Author: Pedro M. Arezes
Publisher: CRC Press
ISBN: 1351675249
Category : Business & Economics
Languages : en
Pages : 608

Book Description
Occupational Safety and Hygiene V contains selected contributions from the International Symposium on Occupational Safety and Hygiene (SHO 2017, 10-11 April 2017, Guimarães, Portugal). The contributions focus on a wide range of topics, including: - occupational safety - risk assessment - safety management - ergonomics - management systems - environmental ergonomics - physical environments - construction safety, and - human factors Occupational Safety and Hygiene V is mainly based on research carried out at universities and other research institutions, but also includes practical studies developed by OHS Practitioners within companies. Accordingly, this book will be a helpful text to get acquainted with the state-of-the-art in research in these domains, as well as with some practical tools and approaches that are currently used by OHS professionals worldwide.

60th Conference on Glass Problems

60th Conference on Glass Problems PDF Book Detail Author: John Kieffer
Publisher: John Wiley & Sons
ISBN: 0470295058
Category : Technology & Engineering
Languages : en
Pages : 290

Book Description
This volume is part of the Ceramic Engineering and Science Proceeding (CESP) series. This series contains a collection of papers dealing with issues in both traditional ceramics (i.e., glass, whitewares, refractories, and porcelain enamel) and advanced ceramics. Topics covered in the area of advanced ceramic include bioceramics, nanomaterials, composites, solid oxide fuel cells, mechanical properties and structural design, advanced ceramic coatings, ceramic armor, porous ceramics, and more.

Sustainable Green Development and Manufacturing Performance through Modern Production Techniques

Sustainable Green Development and Manufacturing Performance through Modern Production Techniques PDF Book Detail Author: Chandan Deep Singh
Publisher: CRC Press
ISBN: 1000487903
Category : Business & Economics
Languages : en
Pages : 376

Book Description
Various Multiple Criteria Decision-Making (MCDM) techniques in one book: 13 MCDM techniques have been applied, namely, WSM, WPM, WASPAS, GRA, SMART, CRITIC, ENTROPY, EDAS, MOORA, AHP, TOPSIS, VIKOR, and new tools: MDEMATEL, Fuzzy MDEMATEL, Modified Fuzzy TOPSIS and Modified Fuzzy VIKOR. To date, no other book possesses this many tools. Various quantitative techniques: Different quantitative techniques have been applied, namely, Cronbach alpha, Chi-square and ANOVA (for demographic analysis), Percent Point Score and Central Tendency (response analysis), Factor Analysis, Correlation and Regression. To date, no other book possesses this many tools. Interpretive Structural Modelling: ISM has been applied for verifying MCDM results through MICMAC analysis and ISM model thus paving the way for model through SEM. Structural Equation Modelling: SEM using AMOS in PASW has been applied for model development. New MCDM techniques developed: In the process during qualitative analysis, new tools have been developed and their results have been compared with other existing MCDM tools and the results are encouraging. The new techniques are MDEMATEL, Fuzzy MDEMATEL, Modified Fuzzy TOPSIS and Modified Fuzzy VIKOR. Qualitative Model Developed: As the title says, Sustainable Green Development and Manufacturing Performance through Modern Production Techniques. It is a need-of-the-hour topic, as industries must maintain their performance (sustainable development) and, while sustaining, they have to keep in mind green issues (that is, environment-related issues, especially during the COVID-19 pandemic) and adopt advanced manufacturing and maintenance techniques. A model for this has been developed which will be helpful to both academicians and industrialists. Real-time Case Studies: Case studies in two industries of differing origins, different manufacturing sectors, different products, and comparing their units in the country of their origin and India. Dr. Chandan Deep Singh is an assistant professor in the Department of Mechanical Engineering, Punjabi University, Patiala, Punjab (India). He is a co-author of Adolescents, Family and Consumer Behaviour (Routledge, 2020) and of Manufacturing Competency and Strategic Success in the Automobile Industry (CRC Press, 2019). Dr. Harleen Kaur is a manager (HR) at DELBREC Industries, Pvt. Ltd., Chandigarh. She co-authored Adolescents, Family and Consumer Behaviour (Routledge, 2020).

Manufacturing Cost Policy Deployment MCPD and Methods Design Concept MDC

Manufacturing Cost Policy Deployment  MCPD  and Methods Design Concept  MDC  PDF Book Detail Author: Alin Posteuca
Publisher: CRC Press
ISBN: 1351651889
Category : Business & Economics
Languages : en
Pages : 302

Book Description
Providing a reasonable level of profitability through productivity is - and will remain - one of the fundamental tasks of the management teams of any production company. Manufacturing Cost Policy Deployment (MCPD) and Methods Design Concept (MDC): The Path to Competitiveness contains two new methodologies to improving the productivity and profitability of production systems that continuously increase competitiveness: Manufacturing Cost Policy Deployment (MCPD) and Methods Design Concept (MDC). Both MCPD and MDC are the result of long-time synthesis and distillation, being implemented successfully, totally or partially, in many companies. The MCPD system, developed by Alin Posteucă, is a manufacturing cost policy aimed at continuous cost improvement through a systemic and systematic approach. The MCPD is a methodology that improves the production flow driven by the need for Manufacturing Cost Improvement (MCI) for both existing and future products through setting targets and means to continuously improve production process productivity for each product family cost. The MDC, developed by Shigeyasu Sakamoto, design the effective manufacturing methods using a tool of engineering steps identifying ideas for increasing productivity called KAIZENSHIRO (improvable value as a target). The MDC results on production methods lead to effectiveness of work measurement for performance (P) and to knowledge and improvement of production control and planning as utilization (U), in order to achieve labor target costs. The combination of MCPD and MDC methodologies can provide a unique approach for the managers who are seeking new ways for increasing productivity and profitability to increase the competitive level of their manufacturing company.

A Revolution in Manufacturing

A Revolution in Manufacturing PDF Book Detail Author: Andrew P. Dillon
Publisher: CRC Press
ISBN: 9780915299034
Category : Business & Economics
Languages : en
Pages : 394

Book Description
Written by the industrial engineer who developed SMED (single-minute exchange of die) for Toyota, A Revolution in Manufacturing provides a full overview of this powerful just in time production tool. It offers the most complete and detailed instructions available anywhere for transforming a manufacturing environment in ways that will speed up production and make small lot inventories feasible. The author delves into both the theory and practice of the SMED system, explaining fundamentals as well as techniques for applying SMED. The critically acclaimed text is supported with hundreds of illustrations and photographs, as well as twelve chapter-length case studies.

Manufacturing Cost Policy Deployment MCPD Profitability Scenarios

Manufacturing Cost Policy Deployment  MCPD  Profitability Scenarios PDF Book Detail Author: Alin Posteuca
Publisher: CRC Press
ISBN: 1351015737
Category : Business & Economics
Languages : en
Pages : 251

Book Description
This book shows how to consistently obtain annual and multiannual manufacturing target profit regardless of the evolution of sales volumes, increasing or decreasing, using the Manufacturing Cost Policy Deployment (MCPD) system. Managers and practitioners within the manufacturing companies will discover a practical approach within the MCPD system that will help them develop and support their long-term, medium-term, and short-term profitability and productivity strategy. The book presents both the basic concepts of MCPD and the key elements of transforming manufacturing companies through MCPD system, as well as supporting the consistent growth of external and internal profit by directing all systematic and systemic improvements based on meeting the annual and multiannual Manufacturing Cost Improvement (MCI) targets and means for each Product-Family Cost (PFC). This book is unique because it presents two types of systematic and systemic improvement projects for MCI that have been applied over the years in various multinational manufacturing companies operating in highly competitive markets, in order to address the consistent reduction of unit manufacturing costs by improving the Cost of Losses and Waste (CLW). Readers will discover the practical approach of MCI based on a structured approach to MCPD system beyond the traditional approach to manufacturing improvements based mainly on improved time and quality. Therefore, from the perspective of the MCPD system, the multiannual manufacturing target profits are met while the annual and multiannual manufacturing target costs are a predetermined stake and not a result of the improvements already made.