Tdkulalo Suzuki: Ed by
Tdkulalo Suzuki: Ed by
Tdkulalo Suzuki: Ed by
TDkulalo Suzuki
TPM IN PROCESS INDUSTR·IES
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Publisher's Message ix
~ Preface' xii
Contributors :xv
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t...; 1 Overview of TPM in Process Industries
Tokutaro Suzuki
1
1
'-' Origin and Development of TPM
Special Features of Process Industries 4
'-' Definition of TPM
Equipment Management in Process Industries
6
7
"'-' KOichiNakazato
What Is Focused Improvement?
Losses and the Six Major Results
45
47
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vi TPM IN PROCESS INDUSTRIES
References 86
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4 Autonomous Maintenance
I0ichi Nakazato
87
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Developing an Autonomous Maintenance Program
Production and Maintenance are Inseparable
87
88
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Classifying and Allocating Maintenance Tasks 89
Establishing BasicEquipment Conditions 93
Implementing Autonomous Maintenance Step-by-Step 100 ""'"'
Preparing an Autonomous Maintenance Master Plan 130 ~
Autonomous Maintenance Audits 142
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Contents vii
Appendix 379
TPM Implementation Outside Japan 379
The PM Prize 380
Index 385
Publisher's Message
V Publisher's Message xi
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coordinating pilot activity and lateral deployment, and carrying out certain
steps concurrently.
'-' In American TPM implementations, autonomous maintenance is often lim-
ited to "task-transfer" - training and reallocating to operators PM work
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requiredfor equipment in its current state. In the more progressive approach rec-
ommended in this book, activities focus first on understanding and improving
conditions, then on defining and reallocating work. As equipment is restored
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and causes of deterioration are understood and controlled through maintain-
ability improvements, the required work changes.
This is particularly important in view of many companies' long-range
plans to minimize operating personnel and increase unattended operation.
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Short-term activities may involve operators in carrying out and improving the
efficiencyof periodic maintenance and repairs. The long-term focus of a mature
TPM program, however, should be improving reliability and maintainability so
that future operator responsibilities can conceivably consist only of inspection.
'--' We are particularly grateful to the team of authors, all full-time consultants
'--' with the Japan Institute of Plant Maintenance, for their willingness to docu-
ment and share their implementation experience. Their insights are based on
'-' many years' work with many different companies. We extend special thanks to
Mr. YoshikiTakahashi, Vice-president and Secretary General of JIPM, for grant-
'-' ing permission to produce this English edition, and to John Loftus for his excel-
\.; lent translation.
Thanks also to the Productivity Press staff and freelancers who helped cre-
'-' ate this book: Julie Zinkus for copyediting and proofreading; Catchword, Inc. for
proofreading and indexing; Karen Jones and Jennifer Albert for editorial man-
'-' I
agement; Bill Stanton and Susan Swanson for design and production manage-
ment; Caroline Kutil, Michele Saar, Gayle Asmus, and Harrison Typesetting,
'-' Inc. for typesetting and art preparation; Jay Cosnett for cover design.
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Norman Bodek
Chairman, Productivity, Inc.
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\.i Connie Dyer
Director of rPM Research and Development
~ Productivity, Inc.
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