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I CERTIFY THAT ALL SEMESTER 5/MAINTENANCE RELIABILITY
OUTCOMES HAVE BEEN COMPLETED:
DATE
_____________________________________________________________________
SIGNATURE
_____________________________________________________________________
AMT Leader
TOYOTA Advanced Manufacturing Technician
Manufacturing Core Exercises
MCE 5: Maintenance Reliability Driving for Zero Downtime
Reaching for Maximum Heijunka
AMT
Outcomes AMT Semester 5 Manufacturing Core Exercise Activity OutcomesMAINTENANCE RELIABILITY
Complete initial Proactive Maintenance training.
State the difference between Corrective Maintenance and Preventive Maintenance.
Define Proactive Maintenance and associated tools/processes.
Properly breakdown a system and define its functions.
Properly define failure modes and root causes of a system.
Properly evaluate a system's failure mode risks and countermeasure accordingly.
Perform an in-training 'RCMNET' activity on a troubleshooting machine.
Perform a second small scale 'RCMNET' on a system/machine of your choosing.
Perform a large scale floor 'RCMNET' on system/machine that is assigned to you.
Report results and findings in the 'RCMNET' to teachers and management.
RC
M O
VE
RV
IEW
7
Qu
es
tio
ns
(C
ore
of
RC
M)
1.
Wh
at
are
th
e f
un
ction
s o
f th
e
equ
ipm
ent?
2.
How
do
es it fa
il?
3.
Wh
at
ca
use
s it
to fa
il?
4.
Wh
at
hap
pen
s w
he
n it fa
ils?
5.
Doe
s it m
att
er
if it fa
ils?
6.
Wh
at
can
be
don
e t
o p
red
ict
or
pre
ve
nt
ea
ch
fa
ilure
?
7.
Wh
at
if t
he
fa
ilure
ca
nno
t b
e
pre
ve
nte
d?
Fu
nc
tio
ns
Fa
ilu
res
Fa
ilu
re M
od
es
Fa
ilu
re E
ffe
cts
De
cis
ion
Dia
gra
m (
C/M
s)
1.
2.
3.
4.
5,6
,7.
Ma
inte
na
nce
Pla
n
FA
CIL
ITA
TO
R
MA
INT
EN
AN
CE
SU
PE
RV
ISO
R
CR
AF
TS
MA
N
OP
ER
AT
ION
S
SU
PE
RV
ISO
R
OP
ER
AT
OR
SP
EC
IAL
IST
Wh
y t
he m
ixed
revie
w
gro
up
of
peo
ple
wh
o k
no
wth
e e
qu
ipm
en
t th
e b
est?
Pee
r k
no
wle
dg
e t
ran
sfe
r an
d t
eam
bu
ild
ing
Red
uc
e c
om
mu
nic
ati
on
ba
rrie
rs
A “
tech
nic
all
y f
easib
le” a
nd
“w
ort
h
do
ing
” P
M l
ist
do
esn
’t m
ak
e
reli
ab
ilit
y h
ap
pe
n o
n its
ow
n.
Peo
ple
mu
st
ch
an
ge
th
e w
ay t
he
y d
o
bu
sin
ess i
n t
he w
ork
pla
ce
Em
plo
yee E
mp
ow
erm
en
t, O
wn
ers
hip
&
Kn
ow
led
ge
h
elp
s t
o i
ns
ure
th
at
po
sit
ive
ch
an
ge
oc
cu
rs i
n t
he
wo
rkp
lace
Red
uce b
arr
iers
to
co
mm
un
icati
on
s a
nd
pro
du
cti
ve w
ork
.
Th
e R
CM
An
aly
sis
Te
am
Maintenance Reliability Basics
COMPLETE MAINTENANCE RELIABILITY TRAINING, INCLUDING
FULL COMPLETION OF THE FAILURE-MODE ANALYSIS EXERCISE.
DATE
_____________________________________________________________________
Include a summary of your RCMNET project here.
COMPLETE AN RCMNET OF A MACHINE ON THE SCHOOLFLOOR.
DATE
_____________________________________________________________________
RCMNET PRESENTATION:
DATE
_____________________________________________________________________
REVIEWERS AT THE PRESENTATION
NAME TITLE
RC
M O
VE
RV
IEW
R
elia
bilit
y-C
en
tere
d M
ain
ten
an
ce (
RC
M):
a p
rocess
use
d t
o d
ete
rmin
e w
hat
must
be d
one
to e
nsu
re
tha
t any p
hysic
al a
ssetcontinues t
o d
o w
hat its u
sers
w
an
t it to d
oin
its
pre
sen
t opera
ting c
onte
xt.
7 Q
ues
tio
ns (
Co
re o
f R
CM
)1
.W
hat
are
the fu
nction
s o
f th
e e
quip
ment?
2.
How
does it fa
il?
3.
Wh
at
causes it to
fail?
4.
Wh
at
happ
en
s w
hen it fa
ils?
5.
Doe
s it m
att
er
if it fa
ils?
6.
Wh
at
can b
e d
one
to
pre
dic
t or
pre
vent
each f
ailu
re?
7.
Wh
at
if t
he fa
ilure
cannot
be p
revente
d?
Pro
active
Ma
inte
na
nce
To
ols
Re
du
ce
MT
TR
of
A R
an
k P
art
s
Au
dit
th
e M
ac
hin
e "
Se
t Ta
rge
t"
Imp
rove
Ma
ch
ine
's B
ac
ku
p
Div
ide
th
e M
ac
hin
e
Ka
ize
n A
Ra
nk
Pa
rts
Eva
lua
te s
pa
re p
art
s r
ec
ord
ed
in
Ste
p 5
Cla
rify
No
rma
l C
on
dit
ion
s
Ma
inta
in t
he
Im
pro
ve
me
nts
Eva
lua
te e
ac
h P
LC
in
pu
t / Im
pro
ve
Pa
ne
lvie
w
Cle
an
Ma
ch
ine
Co
mp
lete
Op
en
W/O
's
MN
ET A
ctivi
ty S
teps
Fu
nc
tio
ns
Fa
ilu
res
Fa
ilu
re M
od
es
Fa
ilu
re E
ffe
cts
De
cis
ion
Dia
gra
m
(C/M
s)
Ma
int.
Pla
n
RC
M F
un
da
men
tals
7 Q
uesti
on
s (
Co
re o
f R
CM
)
1.
Wh
at
are
the f
unctions o
f th
e e
qu
ipm
ent?
2.
How
doe
s it
fail?
3.
Wh
at
ca
use
s it
to f
ail?
4.
Wh
at
ha
ppe
ns w
hen it
fails
?
5.
Doe
s it
matt
er
if it
fails
?6.
Wh
at
ca
n b
e d
on
e t
o
pre
dic
t or
pre
ven
t each
failu
re?
7.
Wh
at
if t
he f
ailu
re c
an
no
t be
pre
ven
ted?
RCMNET PRESENTATION:
DATE
_____________________________________________________________________
REVIEWERS AT THE PRESENTATION
NAME TITLE
COMPLETE AN RCMNET ON A LARGER FLOOR MACHINE.
DATE
_____________________________________________________________________
MAINTENANCE RELIABILITY Essay You have completed your Maintenance Reliability Exercise Outcomes. You have also participated in activities
both at work and at school regarding MR. As your understanding of MR has increased you should have begun
seeing your workplace in the company in a different light. This exercise, perhaps more than any other, really
brings your knowledge and growing capability into real workplace application on the modern, advanced man-
ufacturing floor. This essay will reflect on your emerging talent in managing the manufacturing floor for relia-
ble, continuous operation.
Your assignment is to write an essay about Maintenance Reliability.
Another goal of the essay is to give you the opportunity to develop your good writing skills, both in using ef-
fective writing basics such as grammar, structure, and spelling, and in effectively communicating a message.
Guidelines:
Length: 1-3 pages.
Content: How can what has been learned with this exercise improve manufacturing operations.
What will be the business impact of this improvement? What elements of TPS do the results of a
good Maintenance Reliability practice impact? There is much more that can be included.
This essay does not need to be foot-noted unless your writing needs it. Use any accepted writing
standard or structure that you wish, but be sure to use correct practices and techniques.
Write in any medium that you wish (paper, computer, etc.) The final product should be in electron-
ic form so that it can be both e-mailed and saved as a file. It should be in a form that can easily be
converted to Microsoft Word.
Double check spelling!
Print a copy of your final product.
E-mail your file to the following parties:
AMT Leader: _________________________________ (e-mail address)
School AMT Coordinator: _______________________ (e-mail address)
North American Toyota AMT Regional Assistant: jim.mattingly@tema.toyota.com
Additional parties as directed: ____________________ (e-mail address)
DUE DATE
_____________________________________________________________________
RESOURCES
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