MSSC CPT cheat sheet

OSHA requires employers to furnish required PPE at no cost to employees and to certify a written workplace hazard assessment.

Six-step lockout/tagout: notify affected workers, shut down, isolate energy sources, apply locks and tags, release stored energy, verify zero energy state.

Fire classes and agents: A ordinary combustibles - water; B flammable liquids - foam, CO2, dry chemical; C energized electrical - CO2 or dry chemical, never water; D combustible metals - special dry powder; K cooking oil - wet chemical.

Fall protection is triggered at 4 ft above a lower level in general industry and 6 ft in construction.

A GHS safety data sheet has 16 sections; Section 8 covers exposure controls and personal protection.

Noise exposure: a hearing conservation program is required at an 8-hour TWA of 85 dBA; the permissible exposure limit is 90 dBA.

Acceptable oxygen for confined space entry is 19.5 to 23.5 percent; atmospheres must be tested before entry and monitored continuously.

A GFCI interrupts at roughly 4 to 6 milliamps of leakage current; as little as 30 milliamps through the body can cause respiratory paralysis.

Emergency eyewash must be reachable within about 10 seconds travel (approximately 55 ft) of a corrosive exposure.

Control limits equal the process mean plus or minus three standard deviations; they describe the process, not the customer specification.

Cp = (USL - LSL) / 6 sigma; Cpk = min(USL - x-bar, x-bar - LSL) / 3 sigma.

Capability interpretation: Cpk of 1.33 or higher is generally acceptable, 1.67 or higher is good, and below 1.00 is not capable.

Gage R&R as a percent of tolerance: under 10 percent acceptable, 10 to 30 percent marginal or conditionally acceptable, over 30 percent unacceptable.

Pareto rule: rank causes by frequency; roughly 80 percent of effects come from 20 percent of causes, so act on the vital few.

Out-of-control signals include one point beyond a 3-sigma limit, seven consecutive points on one side of the mean, and six points in a row steadily increasing or decreasing.

Fishbone (cause-and-effect) categories are the six M's: manpower, machine, material, method, measurement, and mother nature (environment).

Six Sigma performance equals 3.4 defects per million opportunities, or 99.99966 percent yield.

Five Whys moves from symptom to root cause; corrective action must address the verified cause rather than the symptom.

Takt time = available production time divided by customer demand rate.

OEE = availability x performance x quality; world-class performance is approximately 85 percent.

Seven wastes (TIMWOOD): transportation, inventory, motion, waiting, overproduction, overprocessing, and defects.

5S sequence: sort, set in order, shine, standardize, sustain.

The bottleneck sets system throughput; added capacity anywhere else produces no additional output.

Cutting speed formula: V = (pi x D x N) / 12, where D is workpiece or cutter diameter in inches and N is spindle speed in rpm.

Turning rotates the workpiece against a single-point tool on a lathe; milling rotates a multi-tooth cutter while the workpiece is fed; drilling produces holes along the tool axis.

SMED reduces changeover by converting internal setup (machine stopped) into external setup (machine still running).

Push systems schedule to forecast; pull systems authorize upstream production only when downstream consumption occurs, typically via kanban.

Preventive maintenance is time- or usage-based; predictive (condition-based) maintenance is triggered by measured condition such as vibration, thermography, oil analysis, or ultrasound.

MTBF = total operating time divided by number of failures; MTTR = total repair time divided by number of repairs.

Availability = MTBF / (MTBF + MTTR); cutting repair time raises uptime without changing reliability.

An estimated 70 to 80 percent of hydraulic failures trace to fluid contamination, controlled with filters, breathers, and fluid sampling.

Over-greasing raises bearing temperature and internal pressure and can rupture seals; follow the specified lubricant type, quantity, and interval.

Common bearing failure causes: misalignment, imbalance, contamination, incorrect lubrication, and improper mounting.

A filter-regulator-lubricator unit removes water and dirt from compressed air, sets line pressure, and adds oil mist for pneumatic components.

TPM pillars include autonomous maintenance, planned maintenance, quality maintenance, and focused improvement.

Vibration at 1x running speed usually indicates imbalance; vibration at 2x running speed usually indicates misalignment.