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.
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
Using Optimal Conditions to Expose Slight Abnormalities
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
Chapter 4: Implementing P-M Analysis Step-By-Step
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