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

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

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.