IENG 451 Stability

4 Ms – Man or woman – Machine – Material – Method

Standards What do we think of when we think standards? Effective standard – simple, clear, visual – Graduates will have the ability to think independently through self-authorship – Graduates will be, on average, one step higher on Perry’s intellectual scale as measured by the RCI

Standards Need not be complicated – Painted silhouette on pegboard for tool location – Visual display of plant capacity, throughput and cycle times – Delivery schedule on receiving dock

5S System Sort Set in order Shine Standardize Sustain

5S – Sort When in doubt, throw it out Red tagging – Red tag removal area – Schedule red tag pause – Explore recycling options – Set up capital assets removal procedure – Commit to regular red tagging

5S – Set in Order A place for everything and everything in its place Tape out positions on floor Provide visual ques whenever possible

5S - Shine Clean regimen Allows better workflow Easier to spot problems Simple form of preventive maintenance

5S – Standardize Standards for work flow Standards for S1, S2, S3 S1 – what is needed and what is not red-tag items disposal procedures

5S – Sustain Perseverance is everything Promote 5S procedures Communicate changes to all who need it; webadvisor Training – Introduction – 2 hrs – 5S core member, implementation – 1 day /month – 5S supervisor – 1 day/month

Total Productive Maintenance Performance standard is 0 breakdowns Maintenance stages – Breakdown maintenance (firefighting) – Preventive maintenance – TPM = (Preventive + Predictive) + total involvement Shift from I operate you fix to we are all responsible

Machine Metrics Availability = (load time – down time)/load time Efficiency = (operating time – lost time)/operating time Effectiveness = availability*efficiency*quality rate

Six Big Losses Equipment breakdowns Setup and adjustment delays Idling Reduced speed Process defects Reduced yield

Machine Loss s Breakdown Minor stoppage Minor failures Hidden failures Motor out Oil change Vibration Loose bolts