PM ANALYSIS
Purpose:
To understand the basic PM Analysis concept and recognize Pm Analysis as tool for the zero defect and zero breakdown ideals of TPM. This course describes how to implement PM Analysis after implementing the conventional way such as why-why analysis, fishbone diagram and others.
Description:
This course explains how PM Analysis is used to overcome the limitation of cause and effect diagram, this course enables the participant to:
>Explain the basics of PM Analysis
>able to to apply PMAnalysis as a tool after the appilication of conventional method.
Chronic Losses and Sporadic Losses
Chronic Losses - repeated occurences within a certain range arising from conditions perceived as normal.
-caused by hidden defects in machinery, equipment, and methods.
-difficultto measure;easily accepted and often ignored.
-cost often appears negligible;true cost is high
-complex combination of causes
-easily fixed, hard to eliminate.
Common errors in chronic loss analysis
>phenomena are insufficiently stratified and analyzed
-failures not carefully observed
-broken into discrete and differing aspects
>some factors related to individual phenomena are overlooked
-some potential causes are overlooked and uncontrolled
>some abnormalities hidden in individual factors and not addressed
-failing to idebtify and respond to abnormal conditions to causal factors.
CHRONIC LOSSES MUST BE REDUCED BY:
>increasing equpimnet reliability and teaming
>restoring equipment to original operating conditions
>establishing a methodology to analyze the failures
>identify optimal operating conditions
>eliminating small defects using problem solving techniques
>breakthrough thinking
>detailed downtime analysis
OPTIMAL CONDITIONS should be Necessary + Desirable/Original + defect free
>example:
Mechanism Necessary Desirable
grease supply grease must be applied at grease nipple should be kept clean
specific loactions condition and volume level of the grease should
be checked
used lubricant should be disposed off properly
grease container should be kept clean and free
of dirt
Sporadic Losses- sudden outbreaks beyond the range of distribution.
PM ANALYSIS
-physically analyzes chronic losses accdg. to inherent principles and natural laws that govern them
-clarifies the mechanics of their occurence and the conditions that must be controlled to prevent them.
P
-stands for Phenomena/Phyiscal(understand the mechanism of the equipment)
M
-stands for:
>Mechanism-analyze the mechanism of the phenomena
-analyze from the point of physics
>Machine, Man, material, method-pursue relationship among these 4 M's.
ANALYSIS
-analyze causes and effects
PM ANALYSIS SEQUENCE
1. Physicall analyze chronic problems such as defects and failures according to the machines operating principles.
2. Define the essential or constituent conditions underlying the abnormal phenomena.
3. Identify all facotrs that logically contirbute to the phenomene in terms of the 4M's: the equipment, mechanisms, material, metjod used, and the peoples actions.
PM ANALYSIS STEPS
1. Clarify the Phenomenon-carefully define and categorize the abnormal occurence.
2. Conduct Physical Analysis- describe the phenomenon in physical terms, example, how the parts or process conditions change in relation to each other to produce the defect/failure.
3. Define the phenomenon's constituent conditions- identify the conditions that will consistently produce the phenomenon.
4. Study the Production input correlation(4M)- look for potential cause and effect relations between the constituent conditions and equipment, materials, work methods and human factors.
5. Set optimal conditions(standard values)- review the equipment; current precision levels to determine where new or revised standards are efficient.
6. Survey causal factors for abnormalities-using appropriate measuring methods, confirm which factors identified in steps 3 and 4 exhibit deviating conditions.
7. Determine abnormalities-review survey results and list all abnormalities to be addressed including slight defects.
8. Propose and make improvements- implement a corrective measure or improvement for each abnormality then institute operating and preventive maintenance procedure to maintain optimal conditions.
STEP 1
Observe how the phenomenon occurs where it occurs
>During what specific equipment operation(drilling, boring, grindng) does the phenomenon occur?
>Does it always occur under the same circumstances(morning start-up, before or after changeover, long runs)
>Does it occur at regular or irregular intervals?
>Does it get better or worse overtime?
>Does it occur on more than one equipment?
>Does it occur only for certain operators?
Specifying defect phenomenon
>Scratches: blows, scrapes, gauges
>Out of roundness: ovoid, triangular, polyhedral
>Tip wear:chipping, relief surface wear, rake surface wear
Defining Phenomena
>Eliminating preconceived notions
>Carefully observing and analyzing the facts onsite
>Sorting and stratifying phenomena thoroughly(5W and 1H)
>Who-any variations among people involved in the operations)
-Any morning/day/night shift differences
-Any difference among new operators, floaters, temporary staff
>What- Any variation due to production materailas?
-Any materail differences? Differences among lots?
-Any variation due to different part dimensions, shapes?
>Where- any variations due to equipment, fixtures, components?
-In what process and what machine elements does the problem occur?
-Any time difference associated with problem?
>Comparing the normal(good products)with the abnormal to pinpoint all significant differences.
>Which- are there any characteristic trends over time?
- Do problems increase or decrease?
- Any changes before, after, or simultaneously?
>How - Any variation in circumstances of occurence?
- Does the problem occur frequently or only rarely?
- Does it appera abruptly or gradually?
STEP 2- CONDUCT PHYSICAL ANALYSIS
Physical Analysis Procedure
STEP DESCRIPTION
1. identify Operating review machine diags and manuals to understand
principles equipments basic operating principles
example: Operation: Welding- Operating principle- create an arc in an
inert gas bet. the base mat'l. and the electrode
and use the heat of arc to melt and fuse(weld)
the base material.(include drawing)
2. identify operating learn functions and mechanisms of equipment
standards and devices by sketching simple machine diags
Operating Standards- 1. Do not allow the current to fluctuate during welding
2. Maintain constant distance bet electrode and base mat'l.
3. Hold electrode at the specified angle when moving it
forward to weld.
3. Identify interacting draw contact diagram to identify what relation
elements ship define the phenomenon
4. quantify the physical identify appropriate physical quantities and
changes involved changes in those quantities
DISTANCE=2mm
Angle= 60 deg
STEP 3: IDENTIFY CONSTITUENT CONDITIONS
Constituent Conditions- consistently gives rise to problem. Fall into the 4M categories of production inputs.
machine-equipment function and precission
Man- level of human skill
Materials- quality of parts leaving previous process
Methods- appropriateness of procedures and standards