Concept of production efficiency

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2018.02.062015.03.04

Table of contents
1. Concept of production efficiency
1. What is the production efficiency?
2. 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
3.
4. Seven large loss of equipment
5.
6. Sudden loss and chronic loss
7.
8. Cleaning is inspection
9. Equipment Ideal
10. Minor defects
11. PM analysis
12. Case of ＰＭ Analysis
13. Example ＰＭ Analysis
14. ＰＭ Analysis Table
15. Maintenance skills
16. Share SlideShare

Concept of production efficiency

What is the production efficiency?
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
large loss to inhibit efficiency

①Shutdown②Product|on adlustment③Equapment fa|lure④Process

fanlure⑤Normal productnon⑥Abnormal productlon⑦Ouallty
defect⑧Reprocessmg
Seven large loss of equipment
①Equipment failure②Set-up & adjustment③Cutting blade
change④Start-up⑤Minor stoppage & idling⑥Speed⑦Deiects

Sudden loss and chronic loss

Sudden loss correspond restore
chronic loss correspond Breakthrough
2.5 Restoration

Before restore then Improve

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.
Cleaning is inspection
Cleaning is very effective as a means to check the deterioration
of the equipment

Equipment 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.)

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.

PM analysis
PM analysis as “a way to look into chronic malfunction phenomena by
physically analyzing such phenomena based on rules
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.
Case of ＰＭ Analysis
Analysis to component level the cause of the failure

Example ＰＭ Analysis
・・・Measures poor Outer diameter of cylindrical grinding machine

Drawing and understand the principles

ＰＭ Analysis Table
Create judgment reference and inspect
Maintenance skills
Solve the problem at the site and then
maintenance activities for the prevention of recurrences.
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