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IENG 451

IENG 451. Stability. 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

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IENG 451

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  1. IENG 451 Stability

  2. Stability • 4 Ms • Man or woman • Machine • Material • Method

  3. 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

  4. 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

  5. 5S System • Sort • Set in order • Shine • Standardize • Sustain

  6. 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

  7. 5S – Set in Order • A place for everything and everything in its place • Tape out positions on floor • Provide visual ques whenever possible

  8. 5S - Shine • Clean regimen • Allows better workflow • Easier to spot problems • Simple form of preventive maintenance

  9. 5S – Standardize • Standards for work flow • Standards for S1, S2, S3 S1 – what is needed and what is not red-tag items disposal procedures

  10. 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

  11. 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

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

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

  14. Machine Loss Breakdown Minor stoppage Minor failures Hidden failures Motor out Oil change Vibration Loose bolts 1 10 30 100s

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