List of Figures Foreword Preface About the Author 1. Introduction - "Your Order is Going to be Late" Downtime = Lost $$ Other Costs of Process Downtime Process Downtime The Course to Zero Downtime 2. Process Set-Up Reduction Pit Stop Basic Concepts Reduce the Set-up Time with a Team New Processes Summary 3. Breakdowns Designing the Process to Prevent Breakdowns Preventing Breakdowns and Recurrences Total Productive Maintenance - TPM Spare parts Summary 4. In-Process Downtime Delays Built Into the Cycle Poorly Programmed Tool Paths Getting the Process Ready/Time to Reach Steady State Machine Speed is Slowed Down Loading/Unloading the Process Walking Extra Operations, such as a second rinse Operator Needed to Start the Process Scrap Excessive Recycle/Rework Loops Assembly Line or Cell Start-Up and Shutdown Conveyance Issues Unbalanced Operations Summary 5. No One to Run It Automation Dealing with Breaks, Lunchtime, Shift Change, and Meetings Dealing with Downtime Due to Meetings/Projects Dealing with Quality Checks Covering for Absences/People Scheduling Issues Absenteeism for Sickness/Health Attendance Metrics/Attendance Policy Poor Safety Culture Change Summary 6. Supply Chain Problems - "For Want of a Nail..." Getting Product to the Line Poor Planning Supplier Problems Unreliable Shipping Companies Inconsistent Customer Orders Waste Disposal Summary 7. Managing the Effort How Much Downtime Do We Have? Identifying the Vital Few Attack the Downtime Monitor Downtime Going Forward Keep Learning Glossary of Acronyms Glossary of Terms