CMRP CHAPTER 7: THE ROLE OF
OPERATIONS CORRECT 100%
The performance of an asset is based on which three factors - ANSWER§ Reliability
(inherent) — how was it designed?
§ Maintenance plan — how will it be maintained?
§ Operating environment — under what environment will it work and how will it be
operated?
Two sub-factors in operating environment - ANSWER- skills of the operators
- operating conditions under which the asset performs.
Who is the first line of defense in watching abnormal conditions of an asset and initiating
corrective actions - ANSWEROperators
Availability (OEE related) - ANSWERthe percentage of the time that an asset is actually
operating (uptime) compared to how long it is scheduled to operate.
Five S (5 S) - ANSWER- structured program to achieve organization-wide cleanliness
and standardization in the
workplace. It consists of five elements: Sort, Set in Order, Shine, Standardize, and
Sustain.
Operator Driven Reliability (ODR) - Operator-Based Reliability (OBR) or Operator-
Based Maintenance (OBM) Overall Equipment - ANSWERInvolving equipment operator
to improve reliability by identifying potential equipment problems
and failures early. Then operator fixes them if minor and gets them repaired if major,
with the help
of maintenance in a planned manner.
Overall Equipment Effectiveness (OEE) - ANSWERMetric for measuring how well an
asset or process is operating.
Evaluates three process factors: availability, performance, and quality. OEE = multiply
three factors & expressed as a percentage. The objective of OEE is to identify sources
of
loss, waste, and inefficiencies that reduce availability, performance and product quality
(defects).
Corrective actions can then be taken to improve the process.
OEE formula - ANSWERavailability x performance x quality in %
Productive Maintenance - ANSWERpreventive maintenance & maintenance prevention
and design improvement
, Aim of productive maintenance - ANSWERto maximize plant and equipment
effectiveness to achieve the optimum life cycle cost for production equipment.
2 objectives of TPM - ANSWER1. Achieve zero defects, zero breakdowns, and zero
accidents in all functional areas of the
organization.
2. Involve people at all levels of organization.
Benefits of TPM - ANSWER1. Increased productivity
2. Reduced manufacturing cost
3. Reduction in customer complaints.
4. Satisfy the customer's needs by 100%
a. Delivering the right quantity
b. At the right time
c. With best, required quality
5. Reduced safety incidents and environmental concerns.
TPM Pillar #1 Autonomous Maintenance (Jishu Hozen) Goals 4 - ANSWER§
Uninterrupted operation of equipment
§ Operators to operate and maintain the equipment
§ Elimination of the defects and potential failures at source quickly
§ Involvement of all employees to solve problems through active participation
TPM Pillar #2 Focused Improvement — Kaizen (Kobetsu) Goals 3 - ANSWER§ Zero
losses — identify and eliminate losses
§ Improve effectiveness of all equipment and plant
§ Reduce O&M costs
six major losses that can become a focus of kaizen teams - ANSWER1. Breakdown
losses
2. Setup and adjustment losses
3. Idling and minor stoppage losses
4. Speed losses
5. Defective product losses (quality) and rework
6. Equipment design losses
Hidden kaizen losses 2 - ANSWERIdling and minor stoppage losses
Speed losses
TPM Pillar #3 Planned Maintenance - ANSWER-Maintenance dept
-beyond autonomous maintenance program
-special skills, significant disassembly, special measuring techniques and tools, etc.
TPM Pillar #4 Quality Maintenance - ANSWERAs operators gain understanding of how
various components of equipment affect the product quality, they begin to eliminate the
current quality issues and then prepare to tackle potential quality concern.
OPERATIONS CORRECT 100%
The performance of an asset is based on which three factors - ANSWER§ Reliability
(inherent) — how was it designed?
§ Maintenance plan — how will it be maintained?
§ Operating environment — under what environment will it work and how will it be
operated?
Two sub-factors in operating environment - ANSWER- skills of the operators
- operating conditions under which the asset performs.
Who is the first line of defense in watching abnormal conditions of an asset and initiating
corrective actions - ANSWEROperators
Availability (OEE related) - ANSWERthe percentage of the time that an asset is actually
operating (uptime) compared to how long it is scheduled to operate.
Five S (5 S) - ANSWER- structured program to achieve organization-wide cleanliness
and standardization in the
workplace. It consists of five elements: Sort, Set in Order, Shine, Standardize, and
Sustain.
Operator Driven Reliability (ODR) - Operator-Based Reliability (OBR) or Operator-
Based Maintenance (OBM) Overall Equipment - ANSWERInvolving equipment operator
to improve reliability by identifying potential equipment problems
and failures early. Then operator fixes them if minor and gets them repaired if major,
with the help
of maintenance in a planned manner.
Overall Equipment Effectiveness (OEE) - ANSWERMetric for measuring how well an
asset or process is operating.
Evaluates three process factors: availability, performance, and quality. OEE = multiply
three factors & expressed as a percentage. The objective of OEE is to identify sources
of
loss, waste, and inefficiencies that reduce availability, performance and product quality
(defects).
Corrective actions can then be taken to improve the process.
OEE formula - ANSWERavailability x performance x quality in %
Productive Maintenance - ANSWERpreventive maintenance & maintenance prevention
and design improvement
, Aim of productive maintenance - ANSWERto maximize plant and equipment
effectiveness to achieve the optimum life cycle cost for production equipment.
2 objectives of TPM - ANSWER1. Achieve zero defects, zero breakdowns, and zero
accidents in all functional areas of the
organization.
2. Involve people at all levels of organization.
Benefits of TPM - ANSWER1. Increased productivity
2. Reduced manufacturing cost
3. Reduction in customer complaints.
4. Satisfy the customer's needs by 100%
a. Delivering the right quantity
b. At the right time
c. With best, required quality
5. Reduced safety incidents and environmental concerns.
TPM Pillar #1 Autonomous Maintenance (Jishu Hozen) Goals 4 - ANSWER§
Uninterrupted operation of equipment
§ Operators to operate and maintain the equipment
§ Elimination of the defects and potential failures at source quickly
§ Involvement of all employees to solve problems through active participation
TPM Pillar #2 Focused Improvement — Kaizen (Kobetsu) Goals 3 - ANSWER§ Zero
losses — identify and eliminate losses
§ Improve effectiveness of all equipment and plant
§ Reduce O&M costs
six major losses that can become a focus of kaizen teams - ANSWER1. Breakdown
losses
2. Setup and adjustment losses
3. Idling and minor stoppage losses
4. Speed losses
5. Defective product losses (quality) and rework
6. Equipment design losses
Hidden kaizen losses 2 - ANSWERIdling and minor stoppage losses
Speed losses
TPM Pillar #3 Planned Maintenance - ANSWER-Maintenance dept
-beyond autonomous maintenance program
-special skills, significant disassembly, special measuring techniques and tools, etc.
TPM Pillar #4 Quality Maintenance - ANSWERAs operators gain understanding of how
various components of equipment affect the product quality, they begin to eliminate the
current quality issues and then prepare to tackle potential quality concern.
