ABSTRACT
This chapter tells how section manager A from company K, a communications equipment manufacturer, worked very hard to implement instant maintenance by following the steps. His steps don't track the steps presented exactly, but pragmatic readers can still benefit from his experiences, so the chapter presents his steps almost verbatim. Step 1: Study Current Conditions; Step 2: Summarize the Problems with Each Line and Machine; Step 3: Analyze Stoppage Mechanisms and Hypothesize Causes; Step 4: Form a Clear Picture of the Phenomenon, Mechanisms, and Causes; Step 5: Set Up an Instant Maintenance System; Step 6: Demonstrate the Maintenance Techniques to Employees. The two-bin system is a kanban method for ordering standard quantities of parts at irregular intervals. Use Why-Why Analysis to figure out the root causes of the problem and how to eliminate it. By setting up a mutually respectful two-way learning environment, one can teach instant maintenance in an enjoyable and even humorous way.
