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Figure 5.26 Material usage chart for example in Figure 5.25

Figure 5.26 Material usage chart for example in Figure 5.25

maintaining and supporting the equipment, which are then standardized as the best practice routine across all shifts.

Figure 5.27 summarizes the relationship between standard operation, techniques for asset care and the right tools, spares, facilities and equipment.

Figure 5.27 Best practice

Standard operation ensures:

• reduced chance of error and risk

• removal of performance irregularity

• elimination of poor operation as a cause of problems

• simplified training within and between shifts

When launching a pilot, we should consider:

• What is the best method of operating our pilot?

• Do the key contacts agree?

• How do we train people to operate this method? (single-point lessons)

• How do we communicate this method to each shift? (visual management)

• How do we make it easy to do it right and difficult to do it wrong? (improvements)

For each piece of equipment we need to establish the best practice for:

• provision of tools

• provision of spares

• monitoring instruments

• outside contracts

Achieved through:

training communication correct application consistent application

Figure 5.27 Best practice

Achieved through:

training communication correct application consistent application

In effect, the best practice routine is similar to your motor car handbook. It explains the best and correct way to operate, maintain and support the car.

Once the 'noise' of poor equipment care and different operative practices are

In seeking to solve the problems which lie behind the six big losses, TPM uses P-M analysis to address problems with mechanisms. This emphasizes the machine/human interface: there are phenomena which are physical, which cause problems which can be prevented; these are to do with materials, machines,

These problems may have a single cause, multiple causes or a complex combination of causes. P-M analysis is concerned with pinpointing the causes, taking countermeasures and evolving best practice routines so that the problems are dealt with once and for all and fed back into an improved OEE.

This approach recognizes practical on-the-job steps as follows:

• Cleaning is inspection Operators are encouraged to look for opportunities to reduce accelerated deterioration and improve equipment design.

• Detect problems and opportunities Work with the team to systematically review problems and opportunities to achieve target performance:

- Define the problem and the conditions under which it occurs

For sporadic losses, the event review provides a simple way of trapping information, problem solving and developing countermeasures. The form shown in Figure 5.28 links five-why problem analysis with the five main countermeasures to sporadic losses. It is designed to promote post-event

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