Tpm lean tools software

Great for the initial stages of Lean implementation, affinity diagrams are used to sort large amounts of data or ideas. In this context, they can help you identify customer value and gather problems with current processes. To eliminate waste as part of Lean manufacturing, you need to understand what could go wrong in your processes.

FMEA analysis allows you to review your flow and anticipate and address issues before they become severe. Create a value stream map to analyze where you can cut non-value added activities. The easiest way to create and maximize flow is to visualize it.

Process flowcharts can help you track flow in an easy-to-understand way. Get started with these two tools:. This template will help you and your team think critically to identify solutions to even the largest problems.

Also known as a cause-and-effect diagram or Ishikawa diagram, the fishbone diagram can help you effectively eliminate issues by examining a problem from multiple angles. In a typical fishbone diagram, you would consider these categories of potential causes: measurements, materials, people, machines, methods, and environment. But you can adapt this diagram to fit your organization. But implementation can often be the most difficult part of the Lean or Lean Six Sigma process.

Use these diagrams to help:. Often used in manufacturing, the 5S approach will help you organize your workspace for maximum efficiency. Some organizations have added a sixth practice—safety—to identify hazards and set controls to ensure workers are safe.

A dashboard can help you track how employees are performing in each of these areas. Create a flow that is designed to be fail-proof. Commonly known by the Japanese term poka-yoke, this tool involves implementing mechanisms that keep your company from producing products with defects, thereby avoiding waste. There are three main types of error-proofing: warnings think of a fire alarm , shutdown controls, and autocorrection controls. An A3 report includes the most essential information about your processes to present progress, eliminate waste, problem-solve, and make better decisions.

The TPM method gets machine operators involved with regular preventative maintenance to ensure equipment reliability, increase productivity, increase capacity, and improve quality. The PDCA cycle is a key element of Lean management—this tool helps companies transition to continuous improvement. Professionals using this repeatable method will analyze a problem or an opportunity to change, test a hypothesis, review and analyze the results, and implement the plan if successful.

A value stream map visualizes the steps involved with delivering a product or service. Sign and Label Printers. Industrial Label Printers. Printers by Application. Automated Labeling. Printers by Feature. Ribbons, Ink, and Cartridges. Barcode Scanners. Refurbished Printers. Printing Software.

Printer Accessories. Floor Tape. Floor Marking Tape. Social Distancing Floor Marking. PaintStripe Floor Marking Stencils. Floor Marking Diecut Shapes. Printer Tape. Caution and Warning Tape. Anti-Slip Tape. DOT Reflective Tape. Barricade Tape.

Underground Warning Tapes. Pipe Marking Tape. Lockout Tagout. Cable Lockouts. Electrical Equipment Lockouts. Lockout Tagout Kits. Lockout Tagout Stations. Lockout Hasps. Lockout Tagout Tags.

Lockout Training. Lockout Tagout Labels. Lockout Tagout Signs. Lockout Tagout Software. Confined Space Covers. Brady Safety Services. Safety and Facility Signs and Labels Software. Wire and Component Label Software. Product Identification Label Software.

Lab Labeling. Scanning Solutions. Print Automation Software. Template Printing. Hazardous Chemical Labels Software. SmartCheck Safety Software. Lockout Tagout Procedures and Tags. Express Labels Mobile. Safety Signs. Security and Admittance Signs. Fire and Emergency Signs. Hazardous Material Signs. Custom Signs. Apply Root Cause Analysis to eliminate recurring sources of quality defects.

Specifically targets quality issues with improvement projects focused on removing root sources of defects. Reduces number of defects. Reduces cost by catching defects early it is expensive and unreliable to find defects through inspection. Focused Improvement Have small groups of employees work together proactively to achieve regular, incremental improvements in equipment operation. Recurring problems are identified and resolved by cross-functional teams. Combines the collective talents of a company to create an engine for continuous improvement.

Early Equipment Management Directs practical knowledge and understanding of manufacturing equipment gained through TPM towards improving the design of new equipment. New equipment reaches planned performance levels much faster due to fewer startup issues. Maintenance is simpler and more robust due to practical review and employee involvement prior to installation. Applies to operators, maintenance personnel and managers.

Operators develop skills to routinely maintain equipment and identify emerging problems. Maintenance personnel learn techniques for proactive and preventative maintenance. Managers are trained on TPM principles as well as on employee coaching and development. Safety, Health, Environment Maintain a safe and healthy working environment. Eliminates potential health and safety risks, resulting in a safer workplace.

Specifically targets the goal of an accident-free workplace. Extends TPM benefits beyond the plant floor by addressing waste in administrative functions. Supports production through improved administrative operations e.

Component TPM Goal Type of Productivity Loss Availability No Stops Availability takes into account Availability Loss , which includes all events that stop planned production for an appreciable length of time typically several minutes or longer. Examples include Unplanned Stops such as breakdowns and other down events and Planned Stops such as changeovers. Performance No Small Stops or Slow Running Performance takes into account Performance Loss , which includes all factors that cause production to operate at less than the maximum possible speed when running.

Examples include both Slow Cycles, and Small Stops. Quality No Defects Quality takes into account Quality Loss , which factors out manufactured pieces that do not meet quality standards, including pieces that require rework. Examples include Production Rejects and Reduced Yield on startup. Small Stops and Slow Cycles For most equipment it is impossible to manually track slow cycles and small stops.

This means that a great deal of potentially useful information, such as time-based and event-based loss patterns, is not available. Operator Focus For most equipment it is impossible to manually track slow cycles and small stops.

Download Free Lean Tools. Which Equipment? More forgiving of limited TPM experience. Less payback than improving constraint equipment. Provides fastest payback. Working on a critical asset as a trial project is a higher risk option.

May result in equipment being offline more than desired as it is improved. Most Problematic Improving this equipment will be well-supported by operators. Solving well-known problems will strengthen support for the TPM project. Unsolved problems are often unsolved for a reason — it may be challenging to get good results.

Item Description Photograph Take photographs that capture the initial state of the equipment and post them on the project board. Clear Area Clear the area of debris, unused tools and components, and any other items that are not needed. Organize Organize remaining tools and components onto shadow boards boards containing outlines as visual cues.

Clean Up Thoroughly clean the equipment and surrounding area including residue from any leaks or spills. Photograph Take photographs that capture the improved state of the equipment and post them on the project board. Audit Schedule a periodic audit first daily, then weekly to verify that the 5S checklist is being followed. During the audit, update the checklist as needed to keep it current and relevant. Keep audits positive and motivational treat them as a training exercise.

Item Description Inspection Points Identify and document key inspection points all wear parts should be included. Consider creating a map of inspection points as a visual aid. Visibility Replace opaque guarding with transparent guarding in cases where inspection points are obscured where feasible and safe to do so. Set Points Identify and document all set points and their associated settings.

Consider indicating settings directly on the equipment as a visual aid for inspection and auditing. Lubrication Points Identify and document all lubrication points. Schedule lubrication to occur during changeovers or other planned stops in other words, avoid creating new sources of unplanned stop time. Consider externalizing lubrication points that are difficult to access or that require stopping the equipment where feasible and safe to do so.

Operator Training Train operators to bring any anomalies or emerging conditions to the attention of the line supervisor. Create Checklist Create a simple Autonomous Maintenance checklist for all inspection, set point, lubrication, and other operator-controlled maintenance tasks creating Standardized Work for the Autonomous Maintenance process.

Audit Schedule a periodic audit first daily, then weekly to verify that the Autonomous Maintenance checklist is being followed. In most cases, the major loss that is selected should be the largest source of unplanned stop time. Create Team Create a cross-functional team to address the problem.

This team should include four to six employees operators, maintenance personnel, and supervisors with the best equipment knowledge and experience…and that are likely to work well together. Collect Information Collect detailed information on symptoms of the problem, including observations, physical evidence, and photographic evidence. Consider using an Ishikawa fishbone diagram at the equipment to collect observations.

Organize Organize a structured problem solving session to: a identify probable causes of the problem, b evaluate probable causes against the gathered information, and c identify the most effective fixes. Schedule Schedule planned stop time to implement the proposed fixes.

If there is an existing change control process, be sure to utilize that process when implementing fixes. Restart Restart production and determine the effectiveness of the fixes over an appropriate time period.

If sufficiently effective, document any changes to procedures and move on to the next major loss. Otherwise, collect additional information and organize another structured problem solving session. Item Description Components that Wear Identify and document all components that undergo wear these should have been established as inspection points in Step Two. Consider replacing wear components with low-wear or no-wear versions. Components that Fail Identify and document all components that are known to regularly fail.

Item Description Wear Based For wear components, establish the current wear level and a baseline replacement interval in some cases replacement may be triggered early by an Autonomous Maintenance inspection as established in Step Two. Predicted Failure Based For failure-prone components, establish a baseline predicted failure interval. Time Based Create a baseline Planned Maintenance Schedule that schedules proactive replacement of all wear and failure-prone components.

Record every instance of replacement, along with information about the component condition at the time of replacement e. Monthly Audit Perform a monthly Planned Maintenance audit: a verify that the Planned Maintenance Schedule is being followed, b verify that the Component Log sheets are being maintained, and c review all new entries in the Component Log and adjust maintenance intervals where appropriate.

Maintenance Interval Adjustments Anytime there is an unscheduled component replacement, consider adjusting the maintenance interval. If the component is not on the Planned Maintenance Schedule, consider adding it. Component Analysis Consider plotting data over time from thermography and vibration analysis to expose emerging problems and issues. Follow Us on LinkedIn.