Lean TPM: A Blueprint for Change
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Table of contents
- Cover
- Contentsv
- Forewordix
- Prefacexi
- Acknowledgementsxiii
- Abbreviationsxvii
- 1 The business of survival and growth1
- 1.1 The new competitive conditions1
- 1.2 Silver bullets, initiative fatigue and fashionable management3
- 1.3 Why programmes fail4
- 1.4 The value of a compelling vision10
- 1.5 Leading the improvement process13
- 1.6 Lean TPM18
- 1.7 Summary: The foundation for a better improvement model21
- 2 Lean TPM24
- 2.1 Achieving the right balance24
- 2.2 The origins of Lean Thinking25
- 2.3 The origins of TPM31
- 2.4 In summary, what does Lean TPM offer?36
- 2.5 Tackling the hidden waste treasure map37
- 2.6 The integrated route map39
- 2.7 Summary47
- 3 The change mandate: A top- down/ bottom- up partnership49
- 3.1 The Lean change mandate49
- 3.2 Changing the business model53
- 3.3 The senior manager role56
- 3.4 The middle/first line manager role68
- 3.5 Calculating the overall equipment effectiveness74
- 3.6 Shopfloor team77
- 3.7 Summary82
- 4 Transforming the business model85
- 4.1 Transformation and the business model85
- 4.2 The scope of the change process85
- 4.3 Change team roles87
- 4.4 Setting and raising standards89
- 4.5 Implementing ÎlocalÌ policy90
- 4.6 Operations team92
- 4.7 Specialists92
- 4.8 Facilitation94
- 4.9 Summary95
- 5 Process stabilisation97
- 5.1 Stabilising processes97
- 5.2 The recipe for low inventory, high flow and stable operations97
- 5.3 Setting work standards104
- 5.4 Leading the implementation of standards107
- 5.5 Establishing operator asset care109
- 5.6 Understanding the voice of the customer110
- 5.7 Visualising the value stream115
- 5.8 The process of stabilisation: The free-flowing materials map119
- 5.9 Locking in the recipe for low inventory, high flow operation delivering zero breakdowns and self123
- 5.10 Summary125
- 6 Process optimisation127
- 6.1 Introduction to the challenge127
- 6.2 Changing drivers128
- 6.3 Springing the strategy trap134
- 6.4 Creating flexible organisations136
- 6.5 The optimisation process137
- 6.6 Early Management (EM)151
- 6.7 Capability development156
- 6.8 Summary161
- 7 Sustaining the improvement drive164
- 7.1 Introduction164
- 7.2 Sustainability at the management level165
- 7.3 The operations level of improvement175
- 7.4 Summary182
- 8 Conclusions184
- 8.1 Reflections184
- Index191
Merging the benefits of two well-known methodolgies, Lean Thinking and Total Productive Maintenance, Lean TPM shows how to secure increased manufacturing efficiency.
Based on their experienc of working with organisations that have successfully achieved outstanding performance, McCarthy and Rich provide the tools and techniques that convert strategic vision into practical reality. Lean TPM accelerates the benefits of continuous improvement activities within any manufacturing environment by challenging wasteful working practices, releasing the potential of the workforce, targeting effectiveness and making processes work as planned.
* Unites world-class manufacturing, Lean Thinking and Total Productive Maintenance (TPM)
* Shows how to achieve zero breakdowns
* Optimises processes to deliver performance and new products efficiently
* Delivers benefit from continuous improvement activities quickly
Lean TPM provides a single change agenda for organisations. It will help to develop robust supply chain relationships and to optimise the value generating process. Supported by an integrated route map and comprehensive benchmark data, this book enables engineers, technicians and managers to explore this potent technique fully.
* Unites the concepts of world-class manufacturing, Lean and TPM.
* Shows how to accelerate the benefits gained from continuous improvement activities.
* Includes an integrated route map for Lean TPM, including benchmark data.
Based on their experienc of working with organisations that have successfully achieved outstanding performance, McCarthy and Rich provide the tools and techniques that convert strategic vision into practical reality. Lean TPM accelerates the benefits of continuous improvement activities within any manufacturing environment by challenging wasteful working practices, releasing the potential of the workforce, targeting effectiveness and making processes work as planned.
* Unites world-class manufacturing, Lean Thinking and Total Productive Maintenance (TPM)
* Shows how to achieve zero breakdowns
* Optimises processes to deliver performance and new products efficiently
* Delivers benefit from continuous improvement activities quickly
Lean TPM provides a single change agenda for organisations. It will help to develop robust supply chain relationships and to optimise the value generating process. Supported by an integrated route map and comprehensive benchmark data, this book enables engineers, technicians and managers to explore this potent technique fully.
* Unites the concepts of world-class manufacturing, Lean and TPM.
* Shows how to accelerate the benefits gained from continuous improvement activities.
* Includes an integrated route map for Lean TPM, including benchmark data.