P-M Analysis: AN ADVANCED STEP IN TPM IMPLEMENTATION, 1st Edition (Paperback) book cover

P-M Analysis

AN ADVANCED STEP IN TPM IMPLEMENTATION, 1st Edition

By Shirose Kunio, Mitsugu Kaneda, Yoshifumi Kimura

Productivity Press

200 pages

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Paperback: 9781563273124
pub: 2004-09-21
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pub: 2017-08-02
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Description

In this large-format implementation manual, TPM experts explain P-M Analysis. (A methodology that makes zero losses a reality in your TPM program.) P-M Analysis is designed to help your TPM teams analyze and eliminate chronic problems that have been neglected or unresolved in the past.

Chronic quality defects and other chronic losses are hard to eradicate, because they typically have multiple, interrelated causes that vary with every occurrence. Common improvement strategies, like cause-and-effect analysis, are usually ineffective in dealing with such complex problems. P-M Analysis was specially developed to overcome the weaknesses of traditional methods. It offers a rigorous 8-step method for ensuring that all possible factors are identified and investigated.

Through P-M Analysis, teams really get in touch with their equipment. Its unique skill-building process improves technological know-how while delivering solutions to persistent problems. The first four steps of this rigorous 8-step program help teams isolate and understand the root causes of defects and failures within main equipment mechanisms and peripheral systems. The final four steps provide a systematic approach for effectively controlling those causes.

A critical concept in P-M Analysis is physical analysis -- a way of thinking about how defects and failures are generated that forces us to look at the physical principles involved and to quantify the changes in the relationship between the equipment mechanisms and product parts involved. When a proper physical analysis is carried out, teams are far less likely to overlook important factors or to waste time pursuing unrelated ones. Although not a cure-all, P-M Analysis has reduced chronic losses to zero and raised technological expertise in many manufacturing environments.

This illustrated implementation manual provides a thorough step-by-step procedure for implementing P-M Analysis, along with practice exercises and graded examples. It is an unparalleled resource for anyone with a basic knowledge of TPM who is ready to fine-tune their loss-reduction activities. Here, finally, is a root-cause analysis method that will help teams achieve the ultimate goal of zero losses.

Table of Contents

Publisher's Message

Chapter 1: 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

Chapter 2: 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

Chapter 3: Fundamentals of Physical Analysis

What is Physical Analysis?

Examples of Physical Analysis

Avoid Errors in Physical Analysis

Conducting a Physical Analysis

The Logical Flow of Physical Analysis

Summary

Chapter 4: 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

Chapter 5: 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

Chapter 6: P-M Analysis Practice

Common Errors and Corrected Examples

Chapter 7: 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

Subject Categories

BISAC Subject Codes/Headings:
BUS053000
BUSINESS & ECONOMICS / Quality Control
BUS070050
BUSINESS & ECONOMICS / Industries / Manufacturing Industries
BUS082000
BUSINESS & ECONOMICS / Industrial Management