P-M Analysis (c): An Advanced Step in TPM Implementation

Achieve Zero Chronic Loss through TPM Designed to help TPM teams analyze and eliminate chronic and often neglected problems, P-M analysistranscends typical improvement strategies with a rigorous 8-step method, which ensures that all causal factors are identified and fully investigated. Through effective PM analysis, worker teams develop greater awareness of their equipment, and practice unique skill-building exercises that will elevate their technical skill while eliminating the root causes of persistent problems. Through P-M Analysis, organizations have been able to completely eliminate chronic losses while raising the overall technological expertise in many manufacturing environments. This illustrated guide, complete with detailed case studies, moves one through the entire process, from problem identification to analysis to action steps It is an unparalleled resource for those managers with a basic knowledge of TPM who are ready to fine-tune their loss-reduction activities.

Table of Contents:
Publisher's Message The Problem of Chronic Loss Chronic Losses and Sporadic Losses Understanding the Nature of Chronic Loss Problems in Reducing Chronic Loss The Importance of Slight Abnormalities Optimal Conditions Using Optimal Conditions to Expose Slight Abnormalities Summary What is P-M Analysis? P-M Analysis Defined Conventional Improvement Approach The Need for a Better Approach How P-M Analysis Works to Eliminate Chronic Losses Using the Conventional Improvement Approach and P-M Analysis Together The Zero Defects Philosophy Fundamentals of Physical Analysis What is Physical Analysis? Examples of Physical Analysis Avoid Errors in Physcial Analysis Conducting a Physical Analysis The Logical Flow of Physical Analysis Summary Implementing P-M Analysis Step-By-Step Overview Step 1: Clarify the Phenomenon Step 2: Conduct a Physical Analysis Step 3: Identify Constituent Conditions Step 4: Study 4Ms for Causal Factors Step 5: Establish Optimal Conditions (Standard Values) Step 6: Survey Causal Factors for Abnormalities Step 7: Determine Abnormalities to Be Addressed Step 8: Propose and Make Improvements Keys to Conducting P-M Analysis P-M Analysis in Action Background of Problem (Hydraulic Solenoid Valve Defects) P-M Step 1: Clarify the Problem P-M Step 2: Conduct a Physical Analysis P-M Step 3: Identify Constituent Conditions P-M Steps 5-6: Set Optimal Conditions; Survey Factors P-M Step 4: Study 4Ms for Causal Factors P-M Steps 7-8: Identify Abnormalities; Make Improvements P-M Analysis Practice Common Errors and Corrected Examples P-M Analysis Case Studies Case 1: Correcting OD Variation on a Cylindrical Grinder (Nachi-Fujikoshi) Case 2: Correcting Wobble on the Disk Rotor Slide of a Turning Transfer Machine (Nissan) Case 3: Stabilizing the Electron Beam in a Vacuum Evaporation Device (Kansai Nippon Denki) Case 4: Correcting Printing Side Estimation Errors on a Rotary Printing Punch (Dai Nippon Insatsu) Case 5: Eliminating Offset Defects in Air Conditioner Compressor Crank Pins (Daikin) About the Authors Index