HOW TO TACKLE MICRO-STOPS

Machine micro-stops are one of the classic “6 Machine Losses” taught as part of Total Productive Maintenance (TPS) or Kaizen training. As micro stops typically don’t catch the attention of management or maintenance they tend to linger, affecting line stability, output and safety, and frustrating operators.

This case-study describes how a typical sensor-related problem was investigated and resolved using a countermeasure that combines technical solution with a people-related one (using TWI Job Instruction).

Coaching Minute ArticleMerlin Deni Becker VelasquezFebruary 23, 2021Machine Problem Solving

HOW TO SOLVE ERRATIC PROBLEMS

Many problems occur only once in a while. The basic conditions are there all the time, but they require other things to happen at the same time for the problem to manifest itself. This makes them devilishly difficult to replicate and can be frustrating for teams engaged in Problem Solving or Total Productive Maintenance efforts.

Merlin Deni Becker VelasquezFebruary 5, 2021Machine Problem Solving

‘JUST IN TIME’ - WHY SHOULD WE CARE?

What is just in time? And how does it help you?

Merlin Deni Becker VelasquezFebruary 5, 2021

FIXING QUALITY PROBLEMS FOR GOOD

Machine maintenance plays a key role in product quality. Inadequate machine settings, failing components, moving sensors or faulty adjustments are all major contributors to the Cost of Poor Quality in most factories.

Merlin Deni Becker VelasquezFebruary 4, 2021Machine Problem Solving

LEARNING TO SEE… IS OUR SYSTEM OK?

One of the basic principles of Lean manufacturing (and Lean Service) is to make problems visible to ensure they can be solved. Paul’s sensei back in Japan used to tell him: “No problem is big problem”.

Merlin Deni Becker VelasquezFebruary 4, 2021Machine Problem Solving

THE REAL REASON FOR TRAINING - IT’S NOT WHAT YOU THINK…

The real reason why we should train our people…. is perhaps not what you think! It certainly is different from what a lot of organisations do. In this article we explore the thinking of C.R.Dooley, the Director of the Training within Industry (TWI) Service during WWII. His guidance, though 75 years old, provides powerful pointers for leaders seeking a competitive edge in 21st century organisations…

HOW TO SOLVE MACHINE PROBLEMS

The speed and quality of maintenance response are a key element of line stability and performance. How long it takes maintenance technicians to restore production and the rate at which problems recur after they have been ‘fixed’ determines machine availability and output.

Getting to Standardised Work: How can TWI Job Instruction help?

Most lean initiatives involve a lot of talk about the need for standardised work. Without standardisation improvements won’t stick and processes and results remain variable. Basic stability is the foundation for rapid improvement: without it, advanced Lean and Six Sigma tools are likely to disappoint. So how do we get to basic stability?

Coaching Minute ArticleDenis BeckerNovember 30, 2020TWI Job Instruction, Standardised Work

What is the purpose of TWI Job Methods and how is it used?

What is TWI Job Methods? How can it be used ? How does TWI Job methods benefit you?

Coaching Minute ArticleMerlin Deni Becker VelasquezNovember 25, 2020TWI Job Methods

Dynamic capability through TWI Job Relations

Dynamic capability, consistently improving faster than our competitors, creates competitive advantage. In times of great uncertainty and change, such as the Covid crisis, the ability to develop & deploy changes fast, could be even more critical.

Improving people skills - the ability to work with and get results through others - is central to developing dynamic capability. How can TWI Job Relations help with this?

Coaching Minute ArticleDenis BeckerNovember 8, 2020TWI Job Relations, Management skills