Lean Manufacturing Tools

Total Productive Maintenance (TPM) is maintaining and improving production and quality through the man, machine & processes to add value to an organizational growth. There are eight  Pillars of TPM  (Total Productive Maintenance) in Lean Manufacturing Pillars of TPM  (Total Productive Maintenance) in Lean Manufacturing are useful in improvement of the machines reliability. Eight Pillars of TPM (Total Productive Maintenance) in Lean Manufacturing are listed as - 1.Autonomous Maintenance (Jishu-Hozen) 2.Focused Improvement  (Kobetsu-Kaizen). 3.Planned Maintenance  (Keikaku-Hozen) 4.Quality Maintenance (Hinshitsu-Hozen) 5.Early Equipmemt Maintenance (EEM) & Five S's (5S) 6.Education & Training (E&T) 7.Safety Health & Environment (SHE) 8.Office TPM. Eight Pillars of TPM (Total Productive Maintenance) in Lean Manufacturing are explained in brief as follows- 1. AUTONOMOUS MAINTENANCE (JISHU-HOZEN) - Targets - To reduce Oil Consumption by 50%. To...

Total Productive Maintenance (TPM) in Lean Manufacturing   - Total Productive Maintenance (TPM) in Lean Manufacturing  is a maintenance philosophy designed to integrate equipment maintenance into the manufacturing process for losses elimination due to equipment and keeping equipment with no or less downtime resulting in improved productivity. The process of Total Productive Maintenance (TPM) in Lean Manufacturing  is change from corrective maintenance, preventative maintenance, predictive maintenance. TPM is reducing or eliminating production time loss due to machine failures and keeping equipment available to manufacture products for all time. Successful TPM is a group effort where the entire organization works together to maintain and improve the equipment.  The first steps in implementing  Total Productive Maintenance (TPM) in Lean Manufacturing  is team formation to improve the process.  Employees join TPM teams. Operators are trained to perform ro...

WHAT IS TQM ? (Total Quality Management) 1. TQM is the management approach for the organization which aims for the continuous improvement in the products and services for the customer satisfaction with all employee involvement as the whole and taking into consideration the quality at center as the way for long term success of organization and improvement of the employees. 2. TQM is the Quality improvement with continuous efforts ,systematic analysis and improved work processes. THREE THEMES OF TQM - 1.The Customer 2.The Process 3.The Employees. PRIMARY ELEMENTS OF TQM- 1.Customer Focused. 2.Total Employee Involvement. 3.Process Centered. 4.Integrated System. 5.Strategic & Systematic Approach. 6.Fact Based Decision making. 7.Continual Improvement. 8.Communication LEADERS OF TQM- I MPORTANCE OF TQM - #Customer satisfaction #Team building #Reduction in customer complaint #Reduction in rejection rate #Helps to face competition #Better motivation to employees #Better facilities to emplo...

WHAT IS QUALITY CONTROL (QC)  ? Quality Control (QC) is- A procedure or set of procedures.   To ensure a  product manufactured. Also used for services performed In Service Industries. Aim is to meet the customer requirements.  QC means Quality Control whereas    QA meant for Quality Assurance . To implement the quality control procedure as an effective QC program, an enterprise first decides which specific standards the product or service must meet.  Then the extent of QC actions must be determined for example, the percentage of units to be tested from each lot. Real data of the percentage of units that fail must reported to Management. Managerial level must decide corrective actions upon failed product or services. Defective units must be repaired or rejected or reused . If too many unit failures or instances of poor service occur, a plan must be decided to improve the production or service process. The QC process must be ongoing to ensure the Cu...