TPM Manual Quality - Hozen

TPM Manual
Chapter 7
Quality-Hozen
(Quality Maintenance)
JIPM-Solutions Co. Ltd.

The Definition of Quality-Hozen (Quality Maintenance)
Definition Action
Establish zero-defect conditions in order

to create equipment and processes that Establish Conditions
do not produce any quality defects
Check and measure those conditions

Daily Checks / Periodic Checks
periodically
Prevent quality defects by maintaining
those conditions within a standard range Preventive Quality-Hozen
of values
Predict the possibility of quality defects
Trend Monitoring / Predictive
by monitoring trends in the measured
Maintenance
values
Take preventive action Preventive Action
7-1 Copyright 2010 JIPM-Solutions

An illustration of The Definition of Quality-Hozen
Establish conditions
Identify the 4-M conditions

affecting quality and specify
their control limits
Condition B
Condition A Condition C
(1) Establish Conditions and Standard Condition D
Values (Establish Conditions)
Condition X
(4) Predict Defects
Standard value
(3) Prevent
Deterioration of
(Rate of deterioration)
Condition Control
(Trend Monitoring)
(5) Preventive
Monitor the state of
Action deterioration, and maintain
zero defects by taking
(2) Daily / Periodic Checks preventive action
Year / Month

The Basic Approach to Quality-Hozen
Sources of Quality Defects
Materials Machinery Methods Men/Women
Develop highly-
Create Create Create competent operators
zero-defect zero-defect zero-defect expert in handing their
equipment and work
materials equipment methods processes
Quality Assurance Source zero- Source zero- Find zero-defect Autonomous

＋ defect materials defect equipment methods Maintenance
Equipment ＋
Management Skills training
Source zero- Improve equipment Improve methods
Find out how quality defect materials Develop sustainment
characteristics relate to material to zero-defect level to zero-defect level capabilities
properties, equipment precision
and processing conditions (the ability to spot
abnormalities in the
Establish zero- Establish zero- Establish zero- causal system and
P-M Analysis defect conditions defect conditions defect conditions rectify them swiftly
for materials for equipment for processing and accurately)
Control points
Spot abnormalities
Condition control to prevent ＋
Controls (for Checks (for occurrence of defects Deal with
checking effects) checking causes) abnormalities and
restore required
Reactive Preventive Zero quality defects conditions
management action ＋
Sustain required
1) Action is too late conditions
2) Action is badly timed

The 4 Ms – The Determinants of Quality
Production standards
Machinery Materials Methods
Improving quality
Processing equipment Raw materials Process conditions
Establish Jigs and tools Materials from previous process Work methods
optimal Measuring instruments Measurement
Men / Women
conditions Skills techniques
Morale
Environment
•Work standards
•Checking standards Standardisation
Training,
Process Measurement
observance of
Sustaining quality
Adjustment
work standards
Feedback Processed article
Feedback Inspection
Inspection
standards
Quality Assurance

Quality-Hozen and the other TPM pillars
Kobetsu-Kaizen Raising Improvement skills
(Focused Improvement)
•Revealing efficiency losses Quality Maintenance
•Restoration
•Pursuing excellence
•Eliminating minor flaws
•Turning adjustment into condition-setting
•Identifying necessary skills Establish zero-defect
Raising analytical ability condition
•P-M Analysis (technical issues)
•Habit of thinking logically decide rules rigorously
•IE (Industrial Engineering) techniques
•The 7 QC tools
Jishu-Hozen
•Quality engineering (design of experiments) ＋
The 7 steps of Autonomous Maintenance
Autonomous Maintenance
•Detect deterioration
•Measure deterioration
•Restore equipment
•Prevent deterioration Maintain zero-defect
Kobetsu-Kaizen Predict and prevent failures and defects conditions
Effective Maintenance
•Diagnostic techniques (management issues)
•Condition-based monitoring - observe rules strictly
•Scheduled checks and overhauls
Early
MP Design and robust design
Management
•Design zero-failure, zero-defect equipment
•Vertical start-up
•Design for manufacturability
Achieve and
Training & Develop operators expert in equipment,
products and processes zero defects
Education

The Evolution of Quality-Hozen
1. QM at Fujikoshi 2. QM Procedure from TPM Instructor Course (this manual) 3. QM at Nissan
1 Check quality standards 1 Verify the existing z Confirm quality standards and characteristics 1 Identify Existing Situation
and quality characteristics situation values
z Create flow diagram of individual processes
2 Eliminate Deficiencies
2 Check quality defect for building in quality
phenomena z Investigate defect situation and phenomena, 3 Analyse Causes of
3 Determine equipment to be and stratify Chronic Defects
managed 2 Investigate the z Draw up QA matrix 4 Eradicate Causes of
4 Identify equipment functions processes where Chronic Defects
and structure, processing defects occur 5 Establish Zero-Defect
conditions and setup 3 Investigate and z Investigate 3M conditions in each process Conditions
procedures analyse 3M z Identify deficiencies through on-site 6 Maintain Zero-Defect
5 Investigate state of conditions investigation Conditions
equipment and restore 4 Plan action to z Create Deficiencies Chart and identify 7 Improve Zero-Defect
6 Do P-M Analysis correct countermeasures Conditions
7 Establish defect causes deficiencies z Verify state of equipment, and restore /
8 Optimise settings, improve it 4. The Figure-of-Eight Method

processing conditions and 5 Analyse situations z Analyse situations where the conditions for 1 Identify Investigate quality situation
z
setup procedures where the building in quality are unclear Existing Identify rules and procedures
z
9 Expose flaws conditions for z Experiment to find optimal conditions Situation z Assess compliance
10 Restore or improve building in quality z Evaluate 2 Restore z Restore to current optimal state
11 Check results are unclear z heck results
12 Establish conditions that 6 Eliminate flaws in z Expose flaws in 3M conditions 3 Analyse z Analyse causes
allow good product to be 3M conditions z Carry out improvements Causes z Revise the ideal conditions
achieved z Evaluate results (standard values)

13 Consolidate checking 7 Finalise 3M z Establish 3M conditions that allow good 4 Eradicate z Thoroughly investigate all
methods conditions zproduct to be achieved Causes causes
14 Determine standard values 8 Consolidate z Find ways to consolidate and fix the checking z Restore and improve
checking methods methods, and z Check results
zcarry out improvements 5 Establish z Revise QM matrix

15 Create Quality-Hozen
Matrix 9 Determine z Determine standard values for checks Conditions z Revise standards
16 Incorporate into checking standard values z Create QM matrix 6 Improve z Consolidate checks
standards for checks z Increase reliability of checks, simplify them, Conditions z Revise check intervals
and reduce number of people involved z Improve checking methods
17 Monitor trends and confirm
results 10 Revise standards z Revise materials standards, checking 7 Maintain z Carry out checks based on
and monitor standards and work standards Conditions check standards

trends z Identify Q components so that standards z Monitor trends
zare kept
z Monitor trends and confirm results
7-6-a Copyright 2010 JIPM-Solutions

The Evolution of Quality-Hozen
1 2 5
Sustain Improve
7 6 3 4
The History of Quality-Hozen
1984: Fujikoshi wins TPM Award; a particular highlight is its development of QM

1986: JIPM publishes Fujikoshi no TPM (‘TPM at Fujikoshi’)
1991: Nissan Motor Corp.’s Tochigi Plant wins Special TPM Award
1993: TPM Instructor Course manual is revised
1993: JIPM publishes Nissan Jidosha no TPM (‘TPM at Nissan Motor Corp.’)
1997: JIPM publishes Hinshitsu Hozen Hachi no Ji Tenkaiho (’The Figure-of-Eight Method for
Quality-Hozen ’)
2003: TPM Instructor Course manual is again revised and updated
2003: JIPM publishes Ryohin 100% no Hinshitsu Hozen (‘Quality-Hozen for Perfect Product’)
The award of the TPM Prize to Fujikoshi and the publication of ‘TPM at Fujikoshi’ were the events that
triggered the development of Quality-Hozen . The methodology has become firmly established and is
continually being enhanced through the efforts of the JIPM to inform industry about it, and the research
and practical application carried out by individual companies.
7-6-b Copyright 2010 JIPM-Solutions

Overview of the Figure-of-Eight Method for Quality-Hozen
1-1 Investigate quality situation 5-1 Revise QM Matrix

1-2 Identify rules and procedures 2-1 Restore
5-2 Revise standards
2-2 Check results
1-2 Assess compliance
Establish
5 Conditions
1 2
Restore
Identify Existing
Situation
Sustain Improve
(Observe rules and procedures rigorously) (Tighten up existing rules and procedures,
Check and replace any missing ones)
7 Maintain Analyse 4 Eradicate

Conditions 6 Improve
• Perform checks
3 Causes Causes
Conditions Investigate causes
• Monitor trends Restore and improve
(Revise the rules to ensure • Reduce number 3-1 Analyse causes Check results
they are observable) • Extend intervals 3-2 Revise standards
• Reduce times
(Make them easier
to observe)
Overview of the Figure-of-Eight Method for Quality-Hozen （Step1,2）

2-2 Check results
Establish
5 Conditions
1 2
Restore
Identify Existing
Situation
Sustain Improve

• Perform checks
3 Causes Causes
• Reduce times
(Make them easier
to observe)
Actions Taken After Checking Results
[Type 1] [Type 2] [Type 3]
Determine conditions Revise sustainment system Sustain and Improve
2 2 2
1 5 1 5 1 5
4 4 4
7 7 7
6 3 6 3 6 3

Overview of the Figure-of-Eight Method for Quality-Hozen （Step3,4,5）

2-2 Check results
Establish
5 Conditions
1 2
Restore
Identify Existing
Situation
Sustain Improve

• Perform checks
3 Causes Causes
• Reduce times
(Make them easier
to observe)
7 - 10 Copyright 2010 JIPM-Solutions
Overview of the Figure-of-Eight Method for Quality-Hozen （Step6,7）

2-2 Check results
Establish
5 Conditions
1 2
Restore
Identify Existing
Situation
Sustain Improve

• Perform checks
3 Causes Causes
• Reduce times
(Make them easier
to observe)
The figure of Eight Method for Quality-Hozen
1-(1)
1-(3) Improvement
Investigate quality situation A B CD E F
Assess Improvement 1 results
• Identify quality characteristics Improvement 2
• Identify quality compliance Revise QM matrix Improvement 3
characteristic values A B C D Standards Improvement 4
• Stratify defect phenomena
PM Analysis
A B C D
A B C D 2-(1)Restore
1-(2) 5-(2)
Identify rules and QM matrix Revise
procedures standards 5. Establish 5-(1)
2. Restore conditions Revise QM Matrix
1. Identify existing 3 2-(2) 4. Eradicate causes
Check
Standards
situation 3+6 results
Sustain Improve 4-(1)(2)(3)
6
(Observe rules and procedures rigorously) (Tighten up existing rules and • Investigate causes
procedures, and replace any • Restore and improve
missing ones)
• Check results
7. Maintain conditions [The 4 Kaizen Principles:]
7-(2) 6. Improve conditions Eliminate
Combine
Monitor trends Rearrange
7-(1) Simplify
Perform checks 3-(1)
*
6-(1)(2)(3) Analyse causes 3-(2)
Trend control graph • Reduce number Revise standards
• Extend intervals 3. Analyse causes
Perform tests to establish optimal values
Standard value • Reduce times P-M Analysis table (1) P-M Analysis table (2)
(Make them easier 1 2 3 4 5 67 8
to observe)
Phenomenon
Countermeasures
Explanation by ABCD
Quality Engineering
Assembly parts
Draw up orthogonal array
Identification
Investigation
Components
Unit Level
Standards
Date 1 2 3 4 5 6 7 8 9 10 11 12
check
Items for
Result
1 2 3 4 5 6 7 8 9 10
Parts
Perform experiments
Inspection
Items
Revise check
Do statistical processing
sheet
Diagram Test results

Results of Investigating Quality Situation
Case1
1 2 5
7 6 3 4
(1) Quality Rate (2) Pareto diagram (3) Stratified bar chart
% % %
100 2.5 100 3
99 2.0 80
Quality Rate
Defect Rate
Defect Rate
2
98 1.5 60
97 1.0 40 1
96
0.5 20 Colour density defects
0
0 0 0
defects
Other defects
Current passage
defects
Runs
Colour density
Year / Month Year / Month
[Monitoring overall quality rate] [Stratifying defect rates] [Monitoring individual defect rates]

Function of Surface Treatment Process
Case1
Process 1 2 5
7 6 3 4
Racking Process Function Principal conditions

H2SO4
Remove oil and • Sulphuric acid concentration
Degreasing grease from Al-Mg- • Temperature
Si alloy • Immersion time
NaOH Dissolve surface of • Caustic soda concentration

aluminium (to
Etching eliminate grease and
• Temperature
• Immersion time
scratches)
H2SO4
• Sulphuric acid concentration
Neutralisation Remove smut (Mg, Si) • Immersion time
H2SO4
• Sulphuric acid concentration
Electrolysis Form alumite • Temperature
• Electrolysis
NiSO4 Ni • Quantity of nickel metal

Electrolytic Deposit nickel salts deposited
pigmentation (pigment) • Temperature
• Immersion time

QM Matrix for Surface Treatment Process
Case1
1 2 5
7 6 3 4
Quality Characteristics
Person
Process Control Item Standard value Interval Colour Colour Compliance
responsible Runs
hue density
Water temperature XX ± 2 ﾟC O X
No.9 pH 3.8 – 4.2 1/shift Manufacturing O △

Wash Circulation rate 20% open Daily Maintenance -
(Water) Water supply rate X m3/h Weekly Technical O O
Immersion time X’ XX” Monthly O △
NiSO4 concentration XX±10 g/l Annually O O
Liquid temperature XX±1ﾟC ± O O
No. 13
Pigmen- pH 4.7 – 5.3 O O
tation Al concentration XX ppm max. O O
Process
Circulation rate 100% open -
Current density XX A/m3 O O O
Process P process XX second O O △
conditions Switchover XX second O O O
C process XX second O O △
NiSO4 concentration XX g/l max. O O -
No. 14
Pigmen- Circulation rate Open : 50% -
tation Surface height 461 mm O -
Process
Water supply rate X m3/h O O

Change in Water Temperature and Colour Density Variation
Case1
1 2 5
7 6 3 4
Before Improvement After Improvement

22 10 22 10
20 20
Dark Dark
18 8 18 8
Water temperature
16 16
Water temperature
Colour density
Colour density
14 6 14 6
12 12
10 4 10 4
8 Colour density 8
Conditions
6 Water 6
changed by Colour density
4 temperature operator Light 4
Light
2 2 Water temperature
0 0
ct
ct
ay
ay
ar
ar
r
r
b
b
n
n
l
l
g
p
g
p
ov
ec
ov
ec
Ju
Ju
Ap
Ap
Fe
Fe
Ja
Ju
Ja
Ju
Au
Se
Au
Se
O
O
M
M
M
M
N
D
N
D
Change to More Tolerant Conditions
Case1
1 2 5
7 6 3 4
Before Improvement After Improvement

(current density XX A/m2) (current density YY A/m2)
Dark Dark
Colour
Colour
L:4.8
L:8.6
t : 15 sec. t : 15 sec.
Light Light
20 25 30 35 40 45 20 25 30 35 40 45
second second

Improvement Results
Case1
Trend in Defect Rates 1 2 5
7 6 3 4
%
4
Other defects
Current passage defects
Runs
3 Colour density defects
Defect Rate →
Before After

Colour Density Control Mechanism
Case1
1 2 5
7 6 3 4
H2SO4 H2SO4
When anodic oxidation is carried out in a
H2SO4 H2SO4
Electrolysis 10% sulphuric acid electrolyte, the film
properties change and become irregular, and
Alumite Layer
the colour of the aluminium substrate itself
Barrier Layer changes, as a result of heat generation and
voltage in the vicinity of the barrier layer
Post-Electrolysis H2SO4 H2SO4 Dissolved Al becomes hydrated, forming an
Wash Al(OH)4 gel, if the water pH is too high or the
immersion time too long (i.e.the alumite turns
(4-stage) into boehmite)
Ni Ni Ni Ni
Pigmentation Ni Ni Ni Ni Ni Passing current through the pigment layer
enlarges the barrier layer and improves the
(Pre-treatment)
pigmentation coverage
Ni is deposited and the colour density is

Pigmentation Ni Ni Ni Ni changed by controlling the time for which
Ni Ni Ni Ni Ni
current is passed, in accordance with Faraday’s
(Full current
Law:
passage)
amount of Ni deposited = current (A) x time (s)
P-M analysis Table
Case1
1 2 5
7 6 3 4
Contributing 4-M Correlations 4-M Correlations Investigation

Phenomenon Physical Analysis (Primary) (Secondary) results
Conditions
1-1-1 pH variation X O
The amount ( C ) of 1. The activity of 1-1-2 Liquid temperature variation X O
1-1 Post-
Sometimes the nickel oxide (B) the porous anodic
electrolysis wash
colour is darker or deposited in the oxidation film 1-1-3 Immersion time variation
conditions are
lighter than porous anodic varies during
unsuitable.
standard oxidation film (A) pigmentation. 1-1-4 Variation in quality of liquid in
tank X O
varies (D)
2-1 Inappropriate 2-1-1 Variation in P treatment time X
control of current
2-1-2 Variation in P treatment time
X
Anodic oxidation film
2-2-1 Soiling of clamping jig O
Level of deposition of metal salts
2-2-2 Soiling of electrical connector
O
to beam
2-2-3 Looseness of V-groove
Dark 2. Variation in flow 2-2 There are O
defects in the attachment bolt
of current into
Standard material current path 2-2-4 Corrosion of beam bracket O
Light 2-2-5 Soiling of electrical connector

O
to pigmentation layer
2-2-6 Anode condition O
2-3 The electrical 2-3-1 Difference in material O
conductivity of
the Al sections 2-3-2 Variation in heat-treatment
condition X
varies

Increase in Precision of Current Passage Control
Case1
1 2 5
7 6 3 4
<Before improvement> <After improvement>

Setting Error: Setting Error:
±2sec. ±0.3 sec.
XX XX
calculation calculation Signal
Signal
Current Current Current
Process Power Process Power
Passage Passage passage
computer control supply computer supply
control table
XX XX
command command
Reagent Output Output

Reagent
Scan time control Scan time
2 sec. control
2 sec.

Trend in Defect Rates
Case1
1 2 5
% 7 6 3 4
4
Other defect
Current Passage defects
3 Runs
Colour density defect
→
Defect Rate
Colour density defect

0
Before After completion After completion
Improvement of Step2 of Step4

Trend Monitoring at No. 10 Water Washing Bath
Case1
1 2 5
7 6 3 4
pH
3.8
3.7
3.6
3.5
3.4
7/1 5 10 15 20 25 Date

Standards for Evaluating Level of Control of Rules and Procedures
Case2
1 2 5
7 6 3 4
Control Description of Control Preventing defects from Preventing defects from being
Level Level occurring passed on
Cannot create Error- -The equipment controls the good- -Defects do not occur
defects proofing of product conditions, and if the -Zero possibility of passing on defects
causes conditions are not satisfied, then
A the equipment will not operate
Cannot pass Error-proofing -Individual defects are identified as -There is a system for preventing
on defects of results and when they occur defective product from being passed
B on. Defective product halted by
equipment and process.
Does not Operator -Operators control the good- -To prevent defective product from
create or pass checks product conditions. If the being passed on, operators check the
on defects conditions are not met, then they quality and halt any defective products.
C make adjustments. -High chance of passing on defects
-There is a possibility of a series of
defects occurring
Out of control No control -Defects cannot be prevented -If a defect occurs, it is always passed
D method on
established

Procedure for Developing Quality-Hozen in Manual Work Processes
Case2
1 2 5
1-(1) Clarify quality 1-(3) Identify work conditions 2-(1) Assess control level 7 6 3 4
characteristics
1-(4) Create Process QA Rate Evaluation 2-(2) Evaluate QA level
1-(2) Investigate defect Table
Prevention of Preventing of
situation
Conditions occurrence passing on
% In-process ppm Passed-
Characteristics
Quality
Assurance
defects on defects 2-(3) Calculate QA rate for process
Process
Level
Control level Prevention of Preventing of
occurrence passing on
3. Investigate relationships between QA level and defect situation

a b c d a b c d
4. Establish targets
Improvement 5. Propose improvements and implement them (right-first-

topics time assurance to prevent occurrence of defects)
6. Check results and evaluate

Process QA rate % In-process ppm Passed-
evaluation table defects on defects
= +
Re-assess
assurance rate
a b c d a b c d
7. Consolidate gains and sustain

Quality Assurance Rate in an Assembly Process
Case3
1 2 5
7 6 3 4
High Level (cannot make / cannot pass on) Low

High
Countermeasures
Warning functions Depends on worker's
already in equipment,
exist skills
transmission unit function
e.g. error-proofing
Importance of automatic
A B C
Function1
Function2
Function3
Function4
(1) Process quality assurance rate = No. of characteristics in grey shaded area X 100
Low
Total no. of characteristics
(2) The symbol indicates the thrust of activities for improving the process QA rate

Trend in Rate of Assembly Defects
Case3
1 2 5
7 6 3 4
(ppm)
Defects passed on to
later processes
△△
Defect Rate
△△
9 10 11 12 1 2
(year/month)

QA Matrix (Process QA Rate Evaluation Table)
Case3
1 2 5
7 6 3 4
Assurance (Check ) Process
Actual Deficiency
Overall Verdict
Importance
1 2 5 6 7 20
Actual /Envisaged
FEMA
SP Assembly
Performance
Press Fitting
Assembly
Shaft
Assembly
Support
Assembly
Parking
Name of Process Deficiencies Remarks
test
Knock pins Part missing Insertion Defect C O A A Error Proofed
Press Fitting
Lever pins Part missing Insertion Defect A O A B A Error Proofed

1
One-way valve Assembled B B B A Test Pattern Changed
2 Support Assembly Fastening Defect A O A A Error Proofed
5 Spring Assembly Fastening Defect B O C Needs Action

O-ring Missing B C Needs Action
6 Shaft Assembly
Pin Missing B B
E-ring Missing A O B Needs Action
7 Parking Assembly Ring Insertion A O B Needs Action
Ball Missing A O A Error Proofed
7 -28 Copyright 2010 JIPM-Solutions

Improving Operator-Dependent Assurance Modes 1
Case3
1 2 5
7 6 3 4
Item Before Improvement After Improvement

O-rings installed here O-ring Beep!
identification
O-rings sensor
Error-proofing
introduced to Sensor for
detect missing confirming jig
O-ring installation
O-rings are installed in the three grooves on An error-proofing device was installed,
the shaft. It was envisaged that one or more of consisting of a detector used after installation
the O-rings might be omitted when doing this to check that all the O-rings are in place.
task.
Woops!
Missing Missing
components components
Error-proofing
introduced to
prevent missing
components in
control valve An error-proofing device was installed, using
assembly sensors fitted to the component box and
11 different components are used in assembly tools. If one of the components or
assembling the control valve; the operator tools has not been used, then the hydraulic
occasionally missed a component and had to tool for fastening the last bolt is prevented
redo the task.. from operating.

Improving Operator-Dependent Assurance Modes 2
Case3
1 2 5
7 6 3 4
Item Before Improvement After Improvement

Moves down Moves up Detect
Supplies after presence of
spring supplying springs Beep!
spring Parts feeder
Error-proofing moves down
introduced to
prevent missing
springs Error-proofing using contact sensors was
In the automatic assembly device used in the introduced, to check that all the springs were
packing process, 12 springs are supplied by a in place after the supply step. If a spring is
parts feeder. At the next station, components missing, an alarm sounds and the machine is
are installed on top of these springs. The team halted.
were concerned that springs might be omitted.
Pneumatic cylinder Detector
Which one’s next? supplies bearing races in senses when
correct order bearing race
has been
taken out
Error-proofing
introduced to
prevent
omission of An automatic feed device was installed to
supply the bearing races, one by one, in the
bearing races correct order. Each time one is taken out, a
It was imagined that, when fitting the bearing
photocell detects it, and the device delivers
races, some might be left out, or the wrong the next one to be fitted. This system
ones used. prevents bearing races from being missed
out, or the wrong ones being used.

Confirmation of Results
Case3
1 2 5
(%) 7 6 3 4
100
(ppm)
Process quality
assurance
95.3
95 Z
Assurance Level
Defect Rate
90 Y
Defects passed
on to later stages
85 X
～
～
0
09 10 11 12 1 2 3 4 5 6 7 8 9 10
(Month)

Using Pareto-diagram Stratification to Observe the Genbutsu
PM Analysis Step 1
Too Many Process Defects Too Many Coil Defects Too Many Voltage
Resistance Defects
Why? Why? Why? Observe

‘Genbutsu’
Coil Case
Bobbin
Too Many Coil Too Many Voltage
Defects Resistance Defects Windings are Too Thick

Understanding the Contact point and the Principles of Processing
PM Analysis Step 2
[ Principles and Parameters ]

A fixed bobbin (1) is
wound with copper wire (4)
Contact Diagram paid out from a rotating flyer (2)
3 that moves axially (3).
2
4
Copper Wire Bobbin
Flyer
Physical Analysis Using ABCD Description
PM Analysis Step 2
Draw Diagram Describe in

To Aid Thinking Process ABCD Format
Pitch (C)
•A fixed bobbin (A)
•Is wound with
Small (D)
copper wire (B)
(Varies)
•Paid out from a
Copper rotating flyer and
Wire (B)
pitch (C)
Bobbin (A) •Is too small (D)
(varies)

Simple Mechanism Diagram (Compact Turntable Winder)
PM Analysis Step 3
Tensioning Arm
Tensioner
Tensioning Pulley Indexing Table
Winder
Cooper Wire Timing Belt
Tensioning
Lever Drive Unit
Shock Guide rod
Absorber
Flyer
Bobbin
Splined Shaft Gearwheel
Timing Belt
DC Motor V Belt
DC
Motor
Cooper Wire
Guide rod
Ball thread
DC Motor

Unit Function Investigation Table
PM Analysis Step 3
Functions
Affects
Functional Contributing
Physical
Unit Necessary Desirable conditions
Quantity?
Supply copper Maintain constant

Tensioner Yes Tension varies
wire tension
Rotate at constant
Winder Rotate flyer Yes Rotation speed varies
speed
Move flyer
Drive unit Move at constant speed Yes Speed varies
axially
Supply
Indexing table Supply to fixed point Yes Bobbin moves
bobbins
Poor materials
Number of contributing conditions = total number of functional units +2
Unsatisfactory
method

P-M Analysis Table
PM Analysis Step 4
Physical Contributing 4-M Correlations

Phenomenon 4-M Correlations (Secondary)
Analysis Conditions (Primary)
1-1-1. Playing spring fixing block
The Pitch[C] 1-1-2. Block fixing bolts loose

of a copper 1-1-3. Springs worn out
The coil wire[B] 1-1-4. Play in shock-absorber plate
1-1. Tension setting
windings are wound about
varies 1-1-5. Shock-absorber spring worn out
too thick a bobbin[A]
1.The required
shows 1-1-6. Shock-absorber spring adjustment bolts loose
tension varies
variation [D] 1-1-7. Play in tension lever fixing
1-1-8. Play in tension arm fixing
1-2-1. Wire not wound correctly onto supply wheel
1-2. Set tension cannot
1-2-2. tension rubbers worn
be maintained
Pitch 1-2-3. Rubber tension adjusting bolts loose
2-1. Variation in rotational…..
speed of motor …..
2-2-1. Timing belt loose worn
Copper wire 2-2. Variation in rotational
2-2-2. Timing pulley worn
Bobbin 2.The lateral speed of ball screw
2-2-3. Pulley loose
speed varies
2-3-1. Ball screw worn
2-3. Variation in speed of 2-3-2. Block fixing bolts loose
The Pitch[C] of a copper movement of flyer 2-3-3. Guide bar bolts loose
wire[B] wound about a
bobbin[A] shows variation[D] 2-3-4. Sliding bearings worn or loose
(remainder omitted)

Investigation Results and Deficiencies Identified
PM Analysis Step 5,6,7,8
Location of Item to be Measureme Measured

Tolerances Corrective Action Result
Check Checked nt Method value
1. Redesign
tensioner device
Kept
Variation in 2. Redesign all
Tensioner Tensometer 510–580 g 120–580 g within
tension rollers
tolerances
3. Clean all guide
holes
Variation in
Winder rotational Tachometer ± 2% ±0 OK
speed
1. Adjust slack in
Variation in
Variation in timing belt
return 0–0.32 Within
Drive unit speed of Dial gauge 2. Halt operation
point mm 0.03 mm
movement for 0.5 sec. at
± 0.05mm
return point
(remainder omitted)

Condition of Windings and Trend in Voltage Resistance Defects
After Improvement
PM Analysis - result
60
50
Number of Defects
Trailed on model
40 winding machine
None of the
windings is too 30
thick. Gap
between windings
and case is 20 Extended to other
maintained. winding machines
10
( Month )

The Development of Quality-Hozen (a 10-step procedure)
Step Contents Comments
(1) Confirm quality standards
・ Specify the quality characteristics to be maintained
and characteristics
(2) Create flow diagram of

・ Identify equipment systems’ mechanisms, functions,
individual processes that
processing principles, sequences, etc.
determine product quality
Prepare
Verify
1 existing ・ Understand circumstances in which a quality defect
situation occurs in processing
(3) Investigate defect situation
・ Stratify defect phenomena
and phenomena, and stratify
・ Identify individual processes giving rise to defect
phenomena
Improve Quality
(4) Set targets and make

action plan
Investigate On this basis, draw up a QA

processes matrix
・ Find relationships between individual processes and
Investigate and Analyse
2 where * Investigate individual defect modes

defects processes where defect
occur modes occur
・ Investigate 3-M conditions, using drawings, standards,

(1) Investigate 3-M conditions manuals, etc.
Investigate
in each process ・ Work out what the 3-M conditions should be, on the
and analyse
3 (2) Identify lapses in these basis of processing principles, equipment
3-M mechanisms/functions, etc.
conditions through on-site
conditions investigation ・ Do on-site investigation to establish 3-M conditions and
highlight failures to maintain them
7 - 40 - a Copyright 2010 JIPM-Solutions

(1) Create Deficiencies Chart ・ Verify sustainment through Jishu-Hozen activities;
Plan action investigate process conditions and setup methods; restore to
and identify countermeasures
4 to correct fix deficiencies
(2) Verify state of equipment, ・ Improve equipment that does not meet equipment
deficiencies
and restore/improve it conditions
Plan Improvements
・ Return to principles and parameters of processing, and

Analyse identify all relationships between quality characteristics and
situations processing conditions / equipment precision
(1) Analyse situations where ・ If there are several problematic characteristics in the same
where the conditions for building equipment, then work out which part of the equipment affects
conditions in quality are unclear which quality characteristic
5 for Experiment to find optimum ・ Use P-M Analysis, FMEA, design of experiments, etc. to
achieving situation pinpoint the relationships between defect causes and the 3
good (2) Evaluate Ms; establish 3-M conditions for building in quality
product are ・ Set provisional tolerances (standards) for equipment
unclear precision and processing conditions, so that the quality
characteristics stay in the standard range
Implement Improvements
(1) Expose flaws in 3-M ・ Check/investigate 3 Ms according to 3-M conditions from

Eliminate conditions analysis results
6 flaws in 3-M ・ Identify deficiencies, restore original state and improve
(2) Improve
conditions ・ If all checkpoints are within provisional tolerances, check
(3) Evaluate results that quality characteristics meet standard values
Establish conditions for the

Finalise 3-M 3 Ms which allow good
7
conditions product to be achieved
7 – 40 - b Copyright 2010 JIPM-Solutions

・ Classify the checkpoints into static precision, dynamic
8 Consolidate Find ways to consolidate and precision and processing conditions; try to consolidate
checking fix the checking methods, checks
methods and carry out improvements ・ At the same time, do improvements to make checks
quicker and easier
・ Using methods such as vibration measurement,

establish substitute characteristics for controlling the
(1) Determine standard equipment precision tolerances (standard values)
Determine values for checks required to keep quality characteristics within standards
9 standard (2) Create QM matrix ・ Assign all checks apart from those needing special
values for (3) Increase reliability of measuring equipment, or strip-down checks requiring
Sustain Quality
skill/time, to the Operations Department

Standardise
checks checks, simplify and reduce

number of people involved ・ Find and implement ways of increasing checking
reliability, simplifying checks, and reducing number of
personnel required
・ Managers must educate operators about the reasons

(1) Revise materials why these checks are necessary, on the basis of the
standards, checking equipment mechanisms, structures and functions, and
standards and work the processing principles
Revise standards ・ Operators should add their own notes to checking
standards manuals
10 (2) Display Q component
and monitor tables so that standards are ・ By monitoring trends, take preventive action before
trends adhered to values exceed the standard ranges
(3) Monitor trends and ・ If any other quality problem arises, unrelated to the
confirm results specified standard values, revise the standard values,
items to be checked, and checking methods
7 – 40 - c Copyright 2010 JIPM-Solutions

Carrying Out Quality-Hozen
Aims
1. Confirm quality characteristics (built in by process or equipment)
QA Matrix 2. Study and assess defects or complaints where quality characteristics are not satisfied
3. Investigate individual processes where defect mode has occurred
Investigate and analyse
Identify 3-M conditions that will produce zero defects in each individual
3-M conditions
process
As current List Identify measures for combating deficiencies
situation deficiencies Study carefully how these measures are actually to be implemented
3-M conditions Deficiencies where conditions for

are deficient achieving good product are hard to define
Kobetsu-Kaizen plan (analyse,
experiment, evaluate)
P-M Analysis
Improve Improve materials
equipment and methods
Revise 3-M conditions
Cannot be
Consolidate and fix
consolidated
Establish 3-M
Checking standards Standards must be capable of
conditions
being observed, and their
Revise observance must be monitored
Work standards
Standards
Basic Approach to Consolidating Checks
Identify checks via P-M Analysis
Identify items that affect quality
Classify as fixed cause or variable cause
Fixed Improve Variable
Classify as static precision, dynamic precision, or processing condition
Static precision Dynamic precision Processing condition

Leads to unacceptable Leads to unacceptable
dimensional precision, etc precision of visual appearance
Improve
Improveand
and Consolidate
Consolidatechecks
checksbyby Fix
Fixby
byquantification
quantification
consolidate to facilitate
consolidate to facilitate using substitute
using substitute and indexing
and indexing
checking
checking characteristics
characteristics
Establish
Establishconditions
conditions
Establish
Establishstatic
static Items
Itemsthat
thatcannot
cannotbe
be
based
based on vibrationlevel,
on vibration level,
conditions
conditions fixed
fixedininany
anyway
way
etc.
etc.
Consolidate
Consolidate
Examples of Consolidating Checks by Vibration Monitoring
Plan view of cylindrical grinder Relation between Roundness and
Vibration after adjustment
Max. vibration set to Roundness Vibration
Vibration 2 mm/s
measurement point 5.0μm
Before Adjustment
μm
Why do some
80 12.1
machines vibrate a
lot and some only a - mm/s
little? 100
2.7μm
After Adjustment
Machines that
vibrate a lot have a μm
large gap between 20 1.8
Investigate vibration bearing and shaft - mm/s
levels and 30
roundness in similar
models. When bearing was
adjusted, vibration
velocity reduced, * Gap between bearing and shaft
Correlation between
roundness and vibration and roundness
Correlation exists improved Before After
velocity adjustment adjustment
between vibration
level and roundness. (μm)
Correlation 6
Bearings of heavily- X=3.0
X=1.6
Roundness
coefficient was 0.87, vibrating machines S=0.13 S=0.22

4 were adjusted to
Frequency
so looked for
regression line 3
bring vibration
2
velocity below 2
mm/s
From regression line, 2 4 6 Measure vibration

Vibration velocity (mm/s) 1 2 3
vibration velocity must once a fortnight, and Roundness (μm)
be kept to 2 mm/s or monitor trends
less to keep roundness Adjust bearing if Comparison of frequency distribution of
within 3 μm of standard. vibration starts to roundness before and after adjustment
approach 2 mm/s

Example of Check Consolidation in Chemical Plant
Check Possibility of Consolidation Consolidation
1 PVC slurry density 1 PVC slurry determined in previous
Materials
30% max. step; no direct relationship with

2 PVC slurry temp. contaminants in the feed stage, so No checks required
70% max. no need for check here
3 Feed water concentration 2 Feed water standards adhered to
1 P11 –1, 2, 3, 4-D stuffing box 1 P11 –1, 2, 3, 4-D stuffing box 1 Consolidate checks so that
Must not overheat converted to self-flushing (does water volumes injected at
Equipment
2 P11 –1, 2, 3, 4-D stuffing box not pump start up and shutdown
Water injection 2l/min. at least require water injection). No are checked as part of
3 Water injection pump: min. pressure overheating occurs, but priming is standard operating
5kg/cm2 needed at start up and shutdown. procedures.
2 Check required 2 Check at start up and
shutdown.
1 Stuffing box overheating check 1 Water injection required at startup 1 Same as Equipment category,
Methods (People)
Once / shift and shutdown, as in Equipment so check to confirm water

2 Stuffing box water flowrate check category. volume of 2l/min. at pump
3 Pump discharge pressure check 2 Confirmation required at startup and shutdown
2 kg/cm2 minimum shutdown 2 Check once per shift
4 Pump current check Once / shift Confirmation of normal operation 3 Check once per shift
5 Water injection pump discharge required
pressure check 5 kg/cm2 3 Check required
minimum
11 Checks 5 Checks

Example of Quality Check Matrix Example (1)
Quality characteristics
Item to be Measurement
Part Standard value
measured interval Surface
Roundness Cylindricality
damage
A
Y mm/s or
Grindstone Vibration Once / month ○
less
spindle
B Y mm/s or
Vibration Once / month ○
Work spindle less
D Table Parallelism A μm or less Once / month ○
E Aux. guide Wear B mm or less At setup ○ ○
F Aux. guide Wear C mm or less At setup ○ ○

Example of Quality Check Matrix Example(2)
Extrusion Machine Die Forming die

Part RT Barrel Screw Temp. Outer Clearance Top die Bottom Clearance Cooling
temp. dia. die water
Temp. Wear Wear Temp. Wear Thickness Vacuum Vacuum Thickness Flow Temp.
Check Point difference nozzle dia. nozzle dia. difference rate
185ºC Dia. Dia. 220ºC 0.02mm 1.13 mm 1.0–0.2 1.0–0.2 1.55 ±0.03 15ºC
Standard value ± 3ºC ±0.3mm ±0.3mm ±3ºC max. ±0.03 max. max. ±2ºC
Once / Once / At setup Once / At setup At setup At setup At setup At setup Once / Once /
Frequency day 6 mth. day cycle cycle
Bumpiness O O O O O O
Quality Characteristics
Lustre O O
Shrinking O O
Warping O O O O O
7 – 46,47 Copyright 2010 JIPM-Solutions

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TPM Manual

JIPM-Solutions Co. Ltd.

Establish zero-defect conditions in order

Check and measure those conditions

Take preventive action Preventive Action

7-1 Copyright 2010 JIPM-Solutions

Identify the 4-M conditions

7-2 Copyright 2010 JIPM-Solutions

Materials Machinery Methods Men/Women

Quality Assurance Source zero- Source zero- Find zero-defect Autonomous

7-3 Copyright 2010 JIPM-Solutions

Machinery Materials Methods

7-4 Copyright 2010 JIPM-Solutions

7-5 Copyright 2010 JIPM-Solutions

8 Optimise settings, improve it 4. The Figure-of-Eight Method

11 Check results are unclear z heck results

achieved z Evaluate results (standard values)

checking methods methods, and z Check results

zcarry out improvements 5 Establish z Revise QM matrix

and monitor standards and work standards Conditions check standards

z Monitor trends and confirm results

7-6-a Copyright 2010 JIPM-Solutions

The History of Quality-Hozen

1984: Fujikoshi wins TPM Award; a particular highlight is its development of QM

7-6-b Copyright 2010 JIPM-Solutions

1-1 Investigate quality situation 5-1 Revise QM Matrix

7 Maintain Analyse 4 Eradicate

1-1 Investigate quality situation 5-1 Revise QM Matrix

7 Maintain Analyse 4 Eradicate

[Type 1] [Type 2] [Type 3]

Determine conditions Revise sustainment system Sustain and Improve

7-9 Copyright 2010 JIPM-Solutions

1-1 Investigate quality situation 5-1 Revise QM Matrix

7 Maintain Analyse 4 Eradicate

1-1 Investigate quality situation 5-1 Revise QM Matrix

7 Maintain Analyse 4 Eradicate

7 - 12 Copyright 2010 JIPM-Solutions

Year / Month Year / Month

7 - 13 Copyright 2010 JIPM-Solutions

Racking Process Function Principal conditions

NaOH Dissolve surface of • Caustic soda concentration

NiSO4 Ni • Quantity of nickel metal

7 - 14 Copyright 2010 JIPM-Solutions

No.9 pH 3.8 – 4.2 1/shift Manufacturing O △

7 - 15 Copyright 2010 JIPM-Solutions

Before Improvement After Improvement

Before Improvement After Improvement

7 - 17 Copyright 2010 JIPM-Solutions

Trend in Defect Rates 1 2 5

7 - 18 Copyright 2010 JIPM-Solutions

Ni is deposited and the colour density is

Contributing 4-M Correlations 4-M Correlations Investigation

Light 2-2-5 Soiling of electrical connector

7 - 20 Copyright 2010 JIPM-Solutions

<Before improvement> <After improvement>

Reagent Output Output

7 - 21 Copyright 2010 JIPM-Solutions

Colour density defect

7 - 22 Copyright 2010 JIPM-Solutions

Draw Diagram Describe in