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TPM for lean manufacturing
Chap２． Concept of production efficiency
Quote From ：TPM Deployment program
TPM encyclopedia Keyword Book
（Japan Institute of Plant Maintenance)
Created by Japanese Gemba Kaizen Web

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２． Concept of production efficiency

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2.1 What is the production efficiency?
Equipment
material
man
energy
【OUTPUT】【INPUT】 【INPUT】 【OUTPUT】
Good company
１．Activities to expand quantitative：
① Activity to improve efficiency of the equipment ・・・ Increase the volume per unit time
② Activities Improve efficiency of human ・・・Increase productivity by jig, and tool
③Up The management efficiency · · · production plan, parts tune up, improve of logistics
２． Activities to expand the qualitative ：
① activities to Improve the quality ・・・Increase the volume to reduce the failure rate
② Efforts to increase unmanning ・・・Study of conditions for unmanned operation
From Little INPUT to Biggest Output！
Normal Conpany

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2.2 8 large loss to inhibit efficiency
①Shutdown②Product|on adlustment③Equapment fa|lure④Process fanlure⑤
Normal productnon⑥Abnormal productlon⑦Ouallty defect⑧Reprocessmg

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2.3 Seven large loss of equipment
①Equipment failure②Set-up & adjustment③Cutting blade
change④Start-up⑤Minor stoppage & idling⑥Speed⑦Deiects

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2.4 Sudden loss and chronic loss
Sudden loss correspond restore
chronic loss correspond Breakthrough
・Order to keep the
original level, restoration
measures must be taken。
Innovative measures must
be taken for decreasing the
failure

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2.5 Restoration
Before restore then Improve

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2.5 Restoration
Literally, the action taken to restore to
the original correct condition. Every
piece at equipment changes slowly
along with the lapse at time, making it
necessary to detect such changes
and restore the equipment to the
original, correct state.
Equipment changes unavoidably
occur, although there may be
differences
in the manner at their occurrence;
some occur rapidly after a certain
period
at time; others occur slowly. This
depends on the characteristics of
equipment or its constituent parts.
it is important to specify how to
measure deterioration, what is the
degree
at deterioration, to be considered,
what is the original, correct state, etc.
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2.6 Cleaning is inspection
Cleaning is very effective as a means to check the
deterioration of the equipment

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2.7 Equipment Ideal
Pursuing of the ideal

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Vision of equipment conditions/Equipment as
Vision of equipment conditions are the requirements to be met
to put the functions and performance of equipment into full play
or to maintain them at the highest level. The functions and
performance of equipment can be shown and maintained at
100% and for a long time, only if the functions of the units and
parts that compose the equipment are kept at desirable states
from the viewpoint of engineering principles and rules.
Vision of equipment conditions represent “sufficient conditions,"
whose existence would be more desirable. Even if the
conditions are not met, the equipment operation is possible
unlike absolute necessity (conditions). it does not necessarily
mean that each and any condition is required.
Although “necessary conditions" are maintained, “sufficient
conditions"
are liable to be disregarded. To reduce seven major losses,
satisfaction of the sufficient conditions is absolutely necessary,
but vision of equipment conditions are not clear — in most
cases they are not set. it is necessary to study each of parts,
assembly parts, and portions of equipment from the following
eight viewpoints:
[1] Usage-condition-related viewpoint (processing conditions,
operating conditions, etc.)
[2] installation precision-related viewpoint (vibration, level, etc.)
[3] Assembling precision-related viewpoint (backlash/precision,
etc., as composite body)
[4] Functional viewpoint (appropriate usage range, and the like)
[5] Environmental viewpoint (dust, heat, and others)
[6] External shape-related view (stains, flaws, biased wear,
etc.)
[7] Dimensional precision-related viewpoint (required precision,
surface roughness, etc.)
[8] Material/strength-related viewpoint (strength, rigidity, etc.)
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2.7 Equipment Ideal

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2.8 Minor defects
Minor defect is
not a problem!!
Major accident! !
Oil leaking Dust, dirt High
temperature
Looseness
God is in the details!

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Minor defects
Minor shortcomings and symptoms considered to only slightly affect
results (defects, failures, minor stoppages). in conventional views, such
defects as dust, stains, backlash, etc, have been considered negligible.
When any one of these effects occurs singly, for example, it usually has
little effect, but when many of them occur at the same time, they can
result in multiple effects, bringing about various consequences such as
defects,failures, and minor stoppages.
2.8 Minor defects

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2.9 PM analysis
• PM analysis as “a way to look into chronic
malfunction phenomena by physically analyzing
such phenomena based on rules
PM analysis is a systematic point of view.

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PM in this case is different from PM
referring to preventive maintenance or
production aintenance. Here, P has the
dual meanings of phenomenon and
physical, while M represents mechanism,
machine, man, material, and method.
PM analysis was developed by Kunio
Shirose of JIPM. He defines PM analysis
as “a way to look into chronic malfunction
phenomena by physically analyzing such
phenomena based on rules and principles
thereby making clear the mechanism of
such phenomena.“
In effect, PM analysis is an attempt to
physically analyze chronic malfunction
phenomena, such as chronic defects and
chronic failures,
based on rules and principles; to make
clear the mechanism of such phenomena;
and to list all the factors that are logically
considered to affect
the mechanism, taking into account
equipment structure, human
beings,materials, and methods.
Conventional factor analysis
(characteristic factor diagram), while being
beneficial because of the case with which
anyone can apply, nevertheless
has tended itself to the insufficient analysis
of phenomena; in other words,it tends to
lead to arbitrary conclusions, making it
difficult to achieve zero chronic losses.
To attain zero chronic losses, PM analysis
is by far more effective.
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2.9 PM analysis

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2.9-1 Case of ＰＭ Analysis
Analysis to component level the cause of the failure

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2.9-2 Example ＰＭ Analysis
・・・Measures poor Outer diameter of cylindrical grinding machine
１．Draw a diagram to understand the Phenomena
・Principle: Scrape off the outer diameter of the workpiece in the
grinding wheel.
Principles: 1)the right amount of grinding is regulated by the amount of
displacement of the sizing device.
2) The amount of grinding on the left is regulated by the
amount of displacement on the right.
3) Dress of the wheel is automatically corrected according to
the amount of dress at regular intervals.
２．Problems:Failure occurs and sometimes non-standard for
large Ellipse in the process.
Drawing and understand the principles

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2.9-3 ＰＭ Analysis Table
Create judgment reference and inspect

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2.10 Maintenance skills
Ratings of skills
Solve the problem at the site and then
aintenance activities for the prevention of recurrences.

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