Questions and Answers of Productive Maintenance

Describe the five qualities that show it is time for a change.
Describe five strategies for effectively communicating TPM. Provide an example scenario on how you would use those five communication strategies.
What are the success factors with implementing TPM?
Describe three strategies for overcoming resistance. Provide an example scenario on how you would use those three strategies.
What are the required elements for change?
Describe three ways you can reduce resistance to change.
Why is it important to address “what’s in it for me?”
Why do people fear change? Describe a situation that you have experience where you had to lead change. What resistance did you encounter?
Why is change management important in launching a TPM initiative?
What is status quo?
You are the manager of your local campus bookstore. After studying hoshin kanri, you have determined that you need a more transparent, clear strategic focus for the bookstore. You have identified
Define catchball. Give a specific example.
What is cross-functional management? Why is it important in hoshin kanri?
How is Deming’s cycle different in hoshin kanri? Explain why it is different.
In hoshin kanri, a key step is to conduct an environmental analysis. What is an environmental analysis?
Describe the key steps for implementing an effective strategy.
What does the hoshin implementation plan record and how often should it be reviewed?
How is the purpose of showing the relationships in a hoshin strategic plan summary matrix different from that in the hoshin plan summary?
What is the purpose of the hoshin plan summary? At what level in the organization should the hoshin plan summary be developed?
What are the criteria for the metrics on your hoshin strategic plan summary?
What is the key reason for showing the relationships in the hoshin strategic plan summary?
What does the hoshin strategic plan summary link? How are these linked? What information is provided in the hoshin strategic plan summary?
What is the purpose of the annual review?
What is the purpose of the 1-year plan? What should be analyzed and considered when developing the 1-year plan?
Describe the six main steps of the hoshin planning process.
What are the five levels of organizational needs? How do these relate to Maslow’s hierarchy of needs?
What are the five main steps for effective planning?
What are the two levels of hoshin kanri? Explain each level.
What does hoshin mean?
Define hoshin kanri.
How is safety aligned with autonomous maintenance?
How do accidents occur? How can accidents be prevented?
What is the focus of the safety, health, and environment pillar? How is it linked to the other pillars?
What are the operator skills that TPM education and training goals consider?
Which TPM pillar focuses on eliminating nonconformances in a systematic manner?
What are the goals of planned maintenance?
What is the focus of autonomous maintenance? What are the main activities?
How is autonomous maintenance used to engage production operators?
Why is 5S the first pillar of TPM?
What information is included in a one-point lesson? What questions does it answer?
What is a one-point lesson?
What is an audit schedule? How does it help in rolling out TPM?
What is a master plan? How does it help in rolling out TPM?
Should everyone in the organization receive the same level of training? Why?
Who in the organization should receive training and education in TPM first?
What must be in place for TPM implementation to be successful?
What is train the trainer?
Why is communication important in introducing and institutionalizing TPM?
Why is visual management important in TPM?
Which type of maintenance is assigned to machines with backups in place, or machines that are of low importance to production? Why?
How are performance losses calculated? Provide and describe the equation.
What information should be included when presenting the purpose of TPM?
What is the role of the TPM steering committee?
What is the first step for preparing an organization for TPM? How is it performed?
How can FMEA be used to identify equipment failures?
How is mean time to repair different than mean time between failures?
Why is reliability important in TPM?
How is the total downtime for repair determined in calculating mean time to repair?
What is the difference between planned and total maintenance?
Is the calculation different for bottleneck versus non-bottleneck equipment? How?
Should the criticality of a piece of equipment be considered with OEE? Why?
How can OEE be used with the theory of constraints?
Why should organizations use OEE?
How is OEE different from utilization?
What are the three categories of major equipment loss?
What information does the OEE metric provide to an organization?
Describe the four main steps in the early management system.
How is DOE used in TPM?
How is QFD used in TPM?
What does the diagnostic process include? Why is it important?
Describe the two types of corrective maintenance.
How can flowcharts be used to help schedule maintenance?
What is work estimating? Why is it important?
How do you select the appropriate equipment for periodic maintenance?
Why is it important to schedule appropriate maintenance?
Describe the three main types of activities that will be required for preventive maintenance to be rolled out properly.
Describe the steps involved in breakdown maintenance in a planned maintenance.
Describe the two types of breakdown maintenance.
Create a table showing the similarities and differences of breakdown maintenance, preventive maintenance, periodic maintenance, predictive maintenance, corrective maintenance, and maintenance
Which SMED step includes making necessary adjustments after the first trial pieces are produced?
What is an internal setup? How is it different than an external setup?
Describe the steps of TOC.
Describe the theory of constraints? What is a constraint?
Historically, the time to repair a circuit board has been normally distributed with an average of 27 minutes. A new piece of equipment has been instituted, and it is desired to test whether the
What information does the p-value in ANOVA provide?
A completed failure modes and effects analysis results in the following assessment rating: occurrence = 4, severity = 8, detection = 10.What is the risk priority number for this FMEA?
What tool is used to drill down through the layers of cause and effect to find the root cause?
What is a cause-and-effect diagram? What are the main categories?
What technique is used to visualize the vital few and trivial many?
Discuss the four potential applications of the process capability index.
What three characteristics of a process can be observed with respect to capability?
Determine the Cp and Cpk values for a diameter with an upper specification limit of 1.50 cm, a lower specification limit of 1.25 cm, a standard deviation of 0.117, and a mean of 1.36 cm.
Why is it important to perform a gage R&R study when working on a process improvement study?
Describe an example of where you could use an affinity diagram in your everyday life.
Describe the five categories for customer preferences in the Kano model.
What is a SIPOC diagram? Describe the elements of the SIPOC diagram.
What is a project charter? What are the main elements? What are its benefits?
What is special cause variation? Why is it important to identify special cause variation?
What is variation? Why is it bad? Describe where you see variation in your everyday life.
What is the goal of Six Sigma?

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