TPM For lean manufacturing chp　2 | concept of production efficiency | lean tools

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TPM for lean manufacturingChap２． 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 fanlure⑤Normal 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

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

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.

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.15

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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