08.DM Pillar FC

TPM Club India
Development Management
Faculty: TPM Club India
TPM Club India © Confederation of Indian Industry

TPM Club India
DEVELOPMENT
MANAGEMENT
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Need for Development Management
• It takes too much time for installation of a new machine
• There are too many troubles while installation
• There is a mismatch on many parameters
• It takes too much time to achieve the rated out put
• It takes more amount of money than the budget
• Sometimes, some of the improvements done have to be repeated

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Reasons for these problems
• There is no integration between the different

departments in an organisation
• They are working like silos
• The good work done by one department is not fully
utilised by the other department
• Different departments come into the process of new
machine or new product development at different times
• Knowledge available in the organisation is not
considered or utilised
• …….. may be many more.

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DEVELOPMENT
MANAGEMENT
NEW MACHINE NEW PRODUCT

DEVELOPMENT DEVELOPMENT

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OBJECTIVE
• To reduce time over run

• To reduce cost over run.

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NEW MACHINE
DEVELOPMENT

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Case study
The available capacity = 5 machines

Out put per machine per month = 1000 units
Total output per month = 5000 units
Market requirement per month = 10000 units
Shortfall per month = 5000 units
What to do ?
What are the options ?
How do we go about ?

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Need for New Machine

• Present machine capacity not enough
• Increase in production levels
• Too many problems in the existing machine

– Produces too many defectives
– Too much breakdowns
– Reliability is too poor
• Change of technology
• Producing a completely new product

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Expectations in a machine
Reliability: Characteristics that do not cause functional decline or stoppages
•Low frequency of failures • Low frequency of minor stoppages

•Low frequency of defects • Fewer adjustments
•Stability of machine cycle time • Ease of static and dynamic accuracy
measurement
Maintainability: Ease of deterioration measurement and restoration by fixing
deterioration
•Ease of detecting machine members with failures quickly
•Ease of parts exchange and prompt confirming of functional restoration
•Promptness in detecting deteriorating machine members
•Ease of oil supply and exchange
•Ease of executing overhaul

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Expectations in a machine
Ease of Jishu-Hozen: Characteristics enabling operators to perform

maintenance activities, such as cleaning, oiling, and inspection, in a short period
•Ease of cleaning, oiling, and inspection
•Ease of collecting chips
•Degree of localization of contamination sources at scattering
•Ease of confirming the end of lubrication systems
•Ease of quality maintenance (ease of measuring accuracy)
Operability: Characteristics allowing speedy and sure execution of correct
handling during equipment operation or setup
•Ease of setup and adjustments
•Ease of replacing cutting blades and grinding wheels, and accompanied
adjustment
•Ease of handling buttons (height, layout, number, shapes, color, etc.)
•Ease of transportation and installation

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Expectations in a machine (Contd)

Resource-saving nature: Characteristics showing high efficiency in using
energy, cutting blades, grinding wheels, oil, and other resources required for
equipment operation
•Low level of resources and energy unit consumption
•Degree of resources recycling
Safety: Characteristics not detrimental to the human body either directly or
indirectly
•Small amount of extraordinary operation, including the repair of failures, minor
stoppages, and quality defects
•Less exposure of revolving and driving sections
•Fewer things that stick out, and that people get caught in
•Excellent removability
•Less discharge or splashing of dangerous or hazardous substances

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Expectations in a machine (Contd)

Flexibility: Anticipation of future product changes, demonstrating ease of
change of equipment when products change
•Greater allowance between currently processed and changed products
•Low level of equipment improvement costs as to the range allowed for change
•Short time required for equipment improvement as to the range allowed for
change

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NEW EQUIPMENT DEVELOPMENT
ACHIEVING
MARKET
REQUIREMENTS
ENHANCING ADDING NEW

EXISTING CAPACITY EQUIPMENTS
(a) (b)

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ENHANCING EXISTING CAPACITY (a)
REVIEW EXISTING
CAPACITY
UTILISATION
WITH RESPECT TO
WITH RESPECT TO IMPROVEMENTS
LOSSES THAT
CAN BE DONE

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Loss detail data collection: Sample of a machine

LOSS DETAILS -
# Loss description uom Time Remarks
1 Breakdown Minutes 150
2 Setup & Adjustment Minutes 0
3 Tool change Minutes 10
4 Startup Minutes 0
5 Idling & Minor stoppage Minutes 24
6 Speed loss Minutes 0
7 Defect & Rework Minutes 46
8 Shutdown loss Minutes 45
9 Management loss Minutes 20
10 Operating motion loss Minutes 0
11 Line org. loss Minutes 0
12 Logistics loss Minutes 0
13 Measurement and adjustment Minutes 20
14 Cycle time Minutes 2
15 Total down time Minutes 315
16 Loading time Minutes 450
17 Operating time Minutes 205
18 Availability loss Minutes 245
19 Availability rate % 45.56
20 Expected Production Pcs 410
21 Actual Production Pcs 398
22 Performance rate % 97.07
23 Defectives Nos 23
24 Quality rate % 94.22

25 O E E % 41.67

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REVIEW OF KAIZENS
KAIZENS
RESTORATIVE RENOVATIVE INNOVATIVE

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REVIEW OF KAIZENS
MORE THAN THE DESIGN LEVEL

850
Innovative Kaizens
DESIGN LEVEL
750
KAIZEN
NORMAL NORMAL Renovative Kaizens
OPERATING LEVEL OPERATING LEVEL
650
COUNTER MEASURE Restorative Kaizens
550

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How do we go about this? – Countermeasures
1. Improve Reliability
2. Improve Maintainability
How to
move
up? 3. Increase Jishu Hozenability
4. Increase Flexibility
5. Increase operability

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During implementation of this step, we implemented

countermeasures and kaizens to eliminate Sources of
Contamination and make Hard to access areas easily
accessible.
Hard to access Source of contamination
Arrangement of water circulation Lubricant Splashing - Foiling

pipes - Compounding

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NEW EQUIPMENT DEVELOPMENT
ACHIEVING
MARKET
REQUIREMENTS
ENHANCING ADDING NEW

EXISTING CAPACITY EQUIPMENTS
(a) (b)

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Background
• We have the experience of working on the similar type of equipments
• If not, we have the experience of working on the similar type of
Subsystems like
– Lubricant system, coolant system, motors etc
• This experience is in the form of actual data

– Kaizen Sheets, MP sheets, abnormality matrix, QA and QM matrix, etc
• We have the experience of many other improvement tools and

process methodologies
– FMEA, FTA, etc How to
effectively
• This experience needs to be utilised
use this

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NEW MACHINE DEVELOPMENT
- Conventional Methodology

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General methodology for New machine

development in a company
Market research Product development
Equipment planning Trial manufacturing
Initial flow Start of production

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NEW MACHINE DEVELOPMENT
- TPM Methodology

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Example of an Initial-Phase Control System

Flow chart Standards, forms and
Step Check points
Related dept. Manufacturing dept. Production Engineering Sect. papers
1 • Necessity of initial 1. Yearly equipment

phase production plan application
Concept Policy flow control sheets;
plannin 2, 3, 4 • Purposes and 2. Equipment plan
g Preparing an equipment plan necessity study sheets;
Studying the equipment • Investment effects 3. Equipment
• Order of priority specification-setting
plan tables;
• Development
deadlines 4. Equipment plan
• Person in charge check sheets
1st DR
2 Determination of
5 • Budget and schedule 5. Equipment plan and
• Countermeasures for budget tables
Action the plan
anticipated problems 6. Process QA matrix
plan Equipment budget plan • Production capacity tables
• Reliability 7. 4M analysis tables;
• Flexibility 8. FMEA sheets
• Operability (process)
Request for purchases 9. Equipment design
• Maintainability reflection sheet and
• Safety measures-recording
• Initial Cost tables
Decision • Running cost 3. Equipment
Equipment specification plan • Required specification-
procurement period evaluation tables
10. Equipment design
6,7,8,9,3,10 and manufacturing
specification sheets
2nd DR
3 External design • FMEA for equipment 11. Common equipment
In-house • Capacity specifications
Design design • Reliability 12. FMEA sheets
• Flexibility (equipment);
Quotation • Operability 13. Basic design check
• Maintainability sheets;
Request for ordering 11 • Safety 9. Equipment design
• Economy reflection sheets and
Basic design measures recording
sheets
12,9,13

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Example of an Initial-Phase Control System (Contd)

Flow chart
Step Check points Standards, ledgers, slips
Related dept. Manufacturing dept. Production Technology Sect.
3 • Shapes, processing 14. Detailed design check

Design tolerance, material sheets;
quality, surface 9. Equipment design
3rd DR roughness, and heat reflection sheets and
treatment of parts measures-recording
Detailed design • Selection of marketing tables
parts
4th DR
14, 9
4 • Intermediate checking; 15. Vendor-site inspection
Fabrication Approved schedule, important check sheets (interim)
Manufacturing drawings Manufacturing parts (assembly,
processing precision)
drawings
Quotation
5 • Equipment capacity, 15. Vendor-site inspection
Decommi process capability check sheets
ssioning Request for ordering 15 • Functions and (completion)
at
Manufacturing performance (operation,
vendor’s 15 maintenance, safety,
site reliability)
MP Meetings
Decommissioning at • Modification schedule,
vendor’s site drawing revision
16
6 Installation • Layout and installation 16. Equipment installation
Installatio • Piping and wiring check sheets
n
Trial manufacturing
7 adjustment • Equipment capacity, 17.Initial-phase production
Initial-phase Initial-phase process capability flow control notification
production Initial-phase • Recording problem sheets;
flow production flow countermeasures 18. Initial-phase production
production 17
control • Designation and lifting flow control tables;
designation of initial-phase 19. Problem
production flow control countermeasure record
Mass production • Operation records tables
18
preparation • Defective ratio (Non-
defective product ratio)
Mass production • Failures, minor
19
operation stoppages
Lifting the initial- • Safety
phase production flow • Handling guidance
17
• Performance, time
control utilization ratio
• Handling and Jishu- 20. Handling explanation
Hozen guidance sheets;
20, 21, 22, 23
21. Periodic inspection and
Delivery overhaul standards
22 Jishu-Hozen standards
23. Work standards

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REVIEW Reviews are conducted in different stages in the normal

course in one style or the other in different stages -
conventionally
REVIEW
PREPARATORY PLANNING EXECUTION FINALISATION

STAGE STAGE STAGE STAGE

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REVIEW: Reviews are conducted in different stages with respect to

the initial consideration for achieving the set objectives.
Two types : DESIGN REVIEW (DR) AND COST REVIEW
(CR)
1. PREPARATORY STAGE:
HERE IN THIS STAGE, THE INPUTS FROM THE CUSTOMER

IS REVIEWED AND HOW TO CONVERT IT IN TO THE
REQUIREMENT IS PLANNED.
2. PLANNING STAGE:
HERE IN THIS STAGE THE FOLLOWING ARE PLANNED.

➢DESIGN OF THE MAIN MACHINE
➢DESIGN OF THE ANCILLARY UNITS
➢DESING OF THE FEATURES

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REVIEW
3. EXECUTION STAGE
HERE IN THIS STAGE, WE HAVE TO KEEP IN MIND TWO

THINGS.
a) PRODUCTION WITHOUT DEFECTS
b) PRODUCTION WITH EASY OPERATIONS
MEANS, WITHOUT DEFECTS, REDUCED CYCLE TIME,

REDUCED LOSSES etc.,
4. FINALISATION STAGE:
HERE IN THIS STAGE, WE HAVE TO PLAN FOR THE

FUTURE BY MAKING BULK PRODUCTIONS.

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Detailed Flowchart of Implementation Plan
Reflection on equipment design and records of measures taken
A Process flowchart
Equipment Evaluation of the

Collection of
specification B QA matrix equipment DR
information
plan specification plan
C 4M analysis
D FMEA for processes

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Fig. 6.15 Evaluation Table of Equipment Specification Plan
Equipment Specification Target-Setting Approval Concept

Planning Planning
and Plan Evaluation Table Production Engineering Sect. time
time
Person in charge
Equipment name Asst. sect.manager
Receiving dept: Section manager
Receiving dept.
Preparation
Person in charge
Concept planning date
Action planning date Manager in charge
Classi Item Content- Concept planning time During implementation planning
fication Target Forecast of the plan Evaluation
Production Cycle time,
Capacity roduction volume
Utilization (%)
Reliability Quality (non-defect
Product rate);
Durability (Years)
Overall
Evalu-
ation
Evalu- A: Above the target; B: Equal to the Target; C: Below the Target
ation
If the overall evaluation result is C, the plan should be worked out again.
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Fig.6.16 Flowchart of Initial-Phase Production Flow Control

Staff in charge
Time Production Mainten- Planning
Initial-phase production control step
dept. ance Dept. dept.
Consultation/cooperation 1. Equipment that incorporates development factors
2. Continues processing equipment
Before 3. Equipment that requires investment of 10 million or more
4. Equipment that greatly affects production, quality, safety, and cost
equipment
installation Designated report Determination of control targets and the person in charge of control
Designation Plant
Issuing designated notification sheets Form 1 manager
Preparation of an execution plan Indication Form 2

Installation Preparation of Note (1)
Decommis- Control Tables A and B Form 3-1
sioning,and Occurrence of equipment
Survey Preparation and attach-
and quality problems Form 4 should be attached to
ment of the Control Card
Form 3-1 (to be indicated as
Counting, analysis, Form 5; Note (2) BM)
and countermeasures To be execution
once per week
Form 4 should be attached to
Improvement Preparation and attachment Form 3-1 (to be indicated as
of the Control Card CM and PM). Forwarding the
Information
Forwarding an analysis report (to be registered
Form 5; Once/month As A4 information)
Reflection on the next machine
Operation Operation Entry in Control Table B

(production volume, etc.) Form 3-2
Occurrence of equipment
and quality problems Preparation and attach- Form 4 should be attached to
ment of the Control Card Form 3-1 (to be indicated as
Counting..conversion
BM
into graphs
Form 3-2;
To be enforced by the team
Counting, analysis, Leader once per week
and countermeasures
Form 5;
to be execution
Preparation and attach- Form 4 should be attached to
Improvement once per week Form 3-1 (to be indicated as
PM, CM
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Fig.6.16 Flowchart of Initial-Phase Production Flow Control (Contd)
Forwarding an analysis report Form 5;

Once/month (to be registered
as A4 information)
Reflection in the next machine
Yes
Target attainment
Operation
No
Lifting Yes
is possible
No
Consultation
Alteration Issuance of alteration notifications Form 1
Lifting Issuance of lifting Form 2

notifications Plant
manager
Note (1) Note (2) Note (3)

Form 3-1 Form 3-2 Form 4 Form 5
Initial Phase Production Flow Initial Phase Production Flow Initial-phase production flow control Initial-phase production flow control analysis
Control Table A Control Table B “Initial-phase Management Card” report
Initial Phase Production Flow Date BM, Entry Initial phase production
PM, example control analysis
Control Table A Equipment name Production Equipment downtime CM
Machine Maintenance
Target and changes
volume Frequency ratio

Machine member name Man- Man- Down Stop- Equip- member performance
hours minites time page ment, name
in performance
Min factor quality
Defective pro- Pheno-

duct ratio menon
and
cause
Counter-
measures
(source: Data announced by Yokohama Rubber Co.,Ltd.)
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Fig. 6.17 Collection and Utilization of Technological Information about Product

Design
Information Study and processing Design data Design elaboration
Catalogs, patents and Improvement of inquiry

magazines Inquiry specifications
Specifications
Literature
(technological data) Technological Design standards
Design manuals
Data (criteria)
Design calculation sheets
Instruction manuals Collection of expertise
Design review (DR) checklists of drawing check DR for each step

One –shot
FMEA data Drawing check data
Debugging acceptable
Debugging quality start-up;
Common parts lists
Test reports
Utilization of standard Defect-free
Drawing (product)
Improvement proposals Technological Maintenance drawings design;
viability judgment
Study, Information;
Design changes Reliability Easy-to-use
MP information Information
Safety meetings design;
TM sheets Minor defect
countermeasure Easy-to-
Reports; Manufacture
FMEA Recurrence design;
prevention
Complaint information reports MP Design
CAD utilization Automated editing
and design
Equipment capacity and
Processing technology
MP information
Cost reduction about
Information equipment
Market requirements
Common
specifications
Accident reports
Safety measure
Actual confirmation
Sheets Reports
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Fig. 6.18 Collection and Utilization Flow of MP Information

Information sources Obtaining methods Study and processing Accumulation of information Utilization of information
Maintenance Design Common Utilization of

ledgers standards specifications common specifi-
Occurrence of cations
failures and defects
Morning market
Expertise Determination of
Meetings
basic specifications
Manufacturing drawings
Corrective improvement
maintenance reports Preliminary study
Basic equipment
Technological specifications Determination of
study meetings, made-to-order MP
Initial-phase data
survey of machine about equipment MP meetings specifications Designs
capability capability and
accuracy
Conversion into
Instruction manuals drawings
Energy-saving Implementation
activities various kinds of check sheets Use of check sheets
reports
Initial-phase production
Occurrence of
Reports Flow control records
accidents
Initial-phase
DR Dr record tables Decommissioning records production
flow control
MTBF data Technological

data; catalogs Technological data; Catalogs Instruction manuals
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Outline of the Equipment Technology System

Evaluating economy of equipment investments MP equipment Equipment improvement
Management plan Equipment Initial-phase equip- Operation and maintenance

Shift to ordinary
Investment plan ment management
Initial-phase operation based on
Frames for equipment management targets operation and (Cost reduction)
investments under new (Cost Planning) (Cost control)
(cost, capability, maintenance standards
Maintenance of normal operations

important projects technology, etc.)
Equipment Operation and Equipment

capacity and Maintenance
Investment plan Evaluation Maintenance
efficiency ledgers records
records of Standards
Design,
Investment debugging Initial Grasping effects on
Equipment economy equipment capacity
Investment budgeting Management
records and efficiency
Manufacturing,
Information, development, and remodeling

debugging
Reflection on operation
Specification Measurement accuracy maintenance
evaluation between plans and
determination, basic and improvement
Reflection on design
Installation,
actuals and on standards
and maintenance
design, cost estimate decommissioning.,
Reflection on economic
Quality maintenance and improvement

Reflection of external technology
debugging
Thermal efficiency maintenance and
standards
Evaluation of Initial production
standards
flow, control, improvement
investment economy
debugging Quantitative capacity maintenance and
improvement
Cost standards Design
Operation reliability improvement
Economy evaluation standards
measures
standards
Comparison of economic Reflection on Measures to reduce equipment failure
evaluation plans and design standards
achievements, and their Measures to improve maintainability
reflection on standards
Submission of Grasping the present situation
Countermeasures and budget application
Streamlining measures
(equipment development and remodeling)
Annual targets of major quality and productivity improvement, operating cost reduction, and accident elimination External technological
information

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The change expected
Before After
Overall equipment efficiency
Start-up period
Overall equipment efficiency (%) ➔
Overall equipment efficiency (%) ➔

— —
— Start-up period —
— —
— —
— Full-scale —
— Target line Overall —
operation Target line
— equipment —
efficiency immediately
— —
 No. of minor defects
 No. of minor defects

after start-up
— conventional —
— picture —
— —
— 0 0 —
— —
— —
— —
— —
— —
— No. of —
— minor defects —

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NEW PRODUCT
DEVELOPMENT

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Initial-phase Management System for Products
NEW PRODUCT
DEVELOPMENT
AS PER MARKET
AS PER THE
NEED ( DESIGNED
CUSTOMER NEED
BY THE COMPANY )

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Initial-phase Management System for Products

1. In the Company designed products, we have to take care
of Possibility sides like.,
❖ Marketability
❖ easy to produce
❖ Mfg related issues
❖ Cost of the product
❖ Life
2. The same has to be done with a CFT involving, Finance,

Marketing, Engineering & Reaserch & Development.
3. Then evaluation has to be done for various products in 10

point scale
4. In evaluation, 50% weight age should be given for

Marketability and remaining 50 % weight age for others.
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Example of the initial-phase Management System for Products

Flowchart of initial-phase management system for products Items to check Standards,
ledgers, slips
Needs Seeds
1
Checking basic market,
Study technology and cost
Study of possibilities 1st DR
research related potentials that can
be overcome
Decision on the order of development priority Development theme
selection sheets
2 Determination of specifications 2nd DR Paper study Conformity study
sheets
Overall concept design 3rd DR
Studying functions, basic Overall concept
Planning strength performance, evaluation system
Board of directors meeting
Development decision and manufacturing
3 New product development meeting methods and processes
Decision on details (assembly) 4th DR

Design Extraction and solutions
of potential problems
Detailed design (parts) 5th DR FMEA sheets
Process design (assembly, parts,
4 processes)
Ordering prototypes
Prototype order
Proto- Inspection of parts control ledger
NO Checking of functions
typing YES
1st prototype fabrication
NO
YES
nd
Checking of performance
2 prototype fabrication
5
Confirmation and specification of performance Conformity study
Extraction and solution of result sheets
Testing actual problems,
Evaluation 6th DR confirmation of steps for
NO Test reports
6 non-production and non-
YES issuance of defective
Mass Mass production registration products Process FMEA
production

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Example of the Development Theme Selection Sheet

1 Marketability 40 points
No. 1 2 3 4 5 Total Remarks
a Price 4
*
b Competitiveness * 3.75
c Market size 4
*
d Innovativeness/uniqueness * 3.25
e Expectance 4.75
*
f Life cycle 4.25
*
g Development possibility 4.5
*
h Patentability * 4.5
33 82.5%
2 Development capacity 30 points

New Application Development Derivation Possessed

Technological potentia of technology
a technology of general already pos- from technology
technology essed possessed 3
* technology
b Jointly with Current project Within the cur-
Personnel engineers in team 4
rently possess-
different fields * ing staff group
c Processing technology 3.75
d Assembly technology 3
*
e 4
Material technology *
4
f Material, and parts supply capacity *
g
21.75 72.5%

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Example of the Development Theme Selection Sheet (Contd)

3 Development schedule 15 points
a 1.5 years One year Ten months Six months Three months
Table Or more
4
*
b Two full-time 1.5 full-time One full-time In parallel with
Manhours employees employees employees other develop- 4.25
ment projects
*
c Priority *
4.5
12.75 85%
4 Others 15 points
Conformity to corporate policy 60% or less 60% 75% 90% 100% 5
a and plans *
Possibility of evolution into
b * 2.25
other products
c Contribution to improvement of
3.75
corporate image
11 73.3%
78.50
Overall evaluation
As seen in the rating of 82.5%, marketability was given a high evaluation. Further, the development schedule was given a high
rating. The degree of conformity of corporate policy was 100%. Based on such evaluation results,development priority was
judged to be high, and development was decided. Marks * and represent evaluators

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Example of FMEA (parts)

FMEA
(Parts)
Product item No. Manufacture Model
name
Evaluation point Reevaluation after measures taken
Parts name Function Defect mode Effects of Cause of Contents
Degree Degree Degree Degree Degree Degree
of parts the defect the defect Impor- of Impor- of
Of occu- of of of of
tance measures tance
Rence effects detection Detection effects occurence
Fig. 6.3 Example of FMEA (Assembly)
FMEA 2/2)
FMEA 1/2)
Product item No. Manufacture Model
name
Evaluation points
Function of Defect Reevaluation after measures taken
Functions Effects of Causes of (above the standard of 20 points) Contents
mode Degree Degree Degree Impor- Degree Degree Degree
parts the defect the defect of Impor- of
Of occu- of of of of
tance measures tance
Rence effects detection Detection effects occurence

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Example of Initial-Phase Product Management

Development Dept.: Quality Assurance Dept.
Technological Dept.: Production Dept.
Omitted
1 Product
drawings E
M Receipt
Carried by 1 product drawings
workers FM FMEA stamp
Judgment TM
Input K M Receipt
# 1 Product drawings
2 Assembly PO
Instruction
Sheet
Drawings should be checked. Necessity or non- 1 Product drawings
necessity of initial-phase product management 2 Assembly instruction sheet
should be judged, and if necessary, an (FM) mark 3 FMEA sheet P
F
should be put on the drawing as a sign of initial-
phase product management indication 1 Product drawings
It should then be registered in computer. 2 Assembly instruction sheet
3 FMEA sheet Production
4 Measurement P
data F
The staff should check the 1 Product drawings 2 Assembly instruction sheet
drawing. FMEA sheet, and 3 FMEA sheet
measurement data, to confirm 4 Measurement data
P
that the product matches the
2 Assembly instruction sheet
drawing and to judge approval or
3 FMEA sheet
non-approval of the product. In 4 Measurement data
the case of approval, they should Production department should conduct an
confirm measures in the Initial-Phase product management in the case
manufacturing process and 4 Measurement data of (F) specification in the assembly instruction
standardization, and discontinue 2 Assembly instruction sheet sheet. FMEA should be implemented, to
the initial-phase product 3 FMEA sheet identify the process defect mode, and
management if complete defect TM 4 Measurement data countermeasures should be taken.
achieve- Subsequently, an FMEA sheet should be
prevention steps are in place. ment-based K
products are then subject to inspection prepared and attached, together with the
ordinary control, so the acceptance initial product measurement data, to the
E
department can inspect and ship TM Shipment actual product. They should be sub-
the products. Lift the initial- R Acceptance
phase product F
management Inspection stamp
s
Temporary
storage MP information

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Trouble Management System

External troubles Internal troubles
TM sheet(1) Acceptance department TM sheet (2) Detection department

for external troubles for internal
Issuance troubles Issuance
Emergency countermeasure Quality Quality Prompt countermeasures and

planning by the related assurance assurance implementation by the staff
departments responsible for the occurrence
Sales, design, Div. manager, section manager

production,quality assurance, of the department responsible
for the occurrence
purchasing, and other
departments
Opening of the markets; Sales, design, production,
Trouble meeting; (planning and workshop)
Countermeasure Morning market; purchasing, quality assurance,
Customers
execution Daytime market; and other departments
Special market;
Horizontal
Countermeasure development
planning
Steps to prevent recurrence
implemented by department Referring to analogous
responsible for the occurrence cases of related staffs
TM sheet (3) Execution of

for recurrence
prevention preventive measures
Standards and standardization; Countermeasure

Check sheet preparation; implementation
Documentation of expertise, etc.
Execution, reports,
and confirmation
Sales, design, production, Reporting Quality

purchasing, and other staffs assurance
Summing up, repair, number of cases,
failure losses, evaluation

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Example of a Trouble Management Sheet

To Mr. ______________________________
QA Dept. Department responsible for occurrence
Reference No.
QA Dept. Related staffs
Date
TM Sheet (3) Recurrence Prevention Section
Department Responsible
for occurrence
Trouble Section manager
Inspection
Item Person in charge
Meeting date and time ______, _______,19_____; from_____:_____ to _____:_____
Meeting parties Market

Training ________________; Existence or nonexistence of data( _____ sheets)
Cause Countermeasures
Department responsible for occurrence

Expenses incurred
Indirect expenses Direct expenses Failure loss symbols
Execution Execution confirmation

Who? What is done by when? by section
or what has been done by when? manager by QA Dept.
Distributed departments Public relations

for horizontal development Sales

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Process QA Matrix
Failure Finished Process Person in charge

Process QA car
mode
Matrix Table Assist.sect.manager
Sect. manager
Parts
Strongly related Related Relations appear likely
Product name
Item number Estimated Machine Processing
cause members order 1 2 3 4 5 6 7 8 9 10
Pheno- Process
Delivery destination menon name
Machine Quality Defect Standards
members characteristics mode

TPM Club India
Process Vs Defect Mode

TPM Club India
Example of 4M Analysis
4M analysis Table Page Product name: Person in charge:

Item No.: Assist. Sect.manager:
Date of preparation: Sect. Manager:
Factors Defect mode Person Equipment Method Materials
1 2 3 4 5 • Forgetting • Insufficiency • Manufacturing

Process • Work pieces
• Over looking of initial method • Auxiliary
functions Flow of work • Error accuracy • Handling materials
• Misunder- • Wear control • Working
Proce- Content Auto- standing • Failures • Manufacturing • Environment
dure of work matic • Insufficiency conditions
1.
2.
3.
4.
5.

TPM Club India
Developing 4M condition

TPM Club India
Example of Process FMEA

TPM-6517-A
FMEA sheet (process)
Prepared (Date):
Product name and
Item No.of the workpiece: Equipment name:
Purposes General products: Important product:
General process: Important process:
Person in charge:
5 4 3 2 1
A Occurrence Chronic (in each lot) Sporadic Sometimes Rarely, but possibility No possibility
frequency (about once/month) (about once/3months) remains
Serious defects Impossible to fit to cars Defects of external No problem
Fatal defects
Degree of appearance (flaws, color,
(strong action of the end, (strength, dimension and (different products,
B importance durability except mistakenly attached Protector location,etc)
water infiltration, durability)
security characteristics) items, defects)
C Difficulty in Cannot be detected by Dependence on the five Inspection based on Detection during fitting Detection before fitting
detection external appearance senses measuring equipment possible possible
Process Process Failure Failure Causes of Countermeasures required for evalua- Counter Improve- Section Confir-
tion marks of 25 or more
name functions mode effects failure Measures ment In charge Mation
AXBXC = Degree of danger taken schedule seal
Front Back Front Back Front Back Front Back

TPM Club India
Reflection on Equipment Design and Record of Measures Taken

No. TPM-6505-A
Reflection on Equipment Design and Measures Taken Issuance
initiating section: Production Technology Sect. Receiving staff
Person in charge: 1 Specification plan
Asst. sect. Manager: 2 Basic functions
Equipment name:
Sect. Manager: Asst. sect.manager: 3 During detailed design
Reflection Details of Person in
Information Importance Problems Countermeasures, Measures Measure Cause Results target reflection charge of Remarks
No. Date Supply taken (D)
(B) and requests implementation (data) (C) (E) (F) measure
(A)
1
2
3
4
5 1 1 OK
6 1 4 OK
7 1 1 OK
8 1 1 OK
9 1 1 OK
10 1 1 OK
11 1 1 OK
12 1 1 OK
13 1 OK
14 1 OK
Details of classification
Dept. supplying Degree of importance Classification Classification Reflection target Classification of reflection content
A Information B
classification Cof measure D causes
of E
classification F
1 Manufacturing dept. Reflection must be 1 Changes in mecha- 1 Defective plan 1 Only the machine 1 Process capability 6 Safety improvement
(internal) 1 realized by all means nism, structure concerned improvement
Manufacturing dept. Reflection is desired 2 Changes in motion 2 Defective design 2 The machine Quantitative 7 Operability
2 (external) 2 functions concerned and the 2 Capacity improvement
If possible next machine improvement
3 3
3 Design dept. 3 Reference 3 Changes in the Defective The machine 3 Reliability
(internal) requested control circuit manufacturing concerned,analogous improvement
machines, and the
4
4 4 4 Maintainability(dura-
Design dept. Changes in surface Specification next time
(external) heat treatment changes bility) improvement
5 Production dept. 5 Changes in 5 Improvement in
Materials, shapes economy

TPM Club India
Evaluation Table of Equipment Specification Plan
Equipment Specification Target-Setting Approval Concept

Planning Planning
and Plan Evaluation Table Production Engineering Sect. time
time
Person in charge
Equipment name Asst. sect.manager
Receiving dept: Section manager
Receiving dept.
Preparation
Person in charge
Concept planning date
Action planning date Manager in charge
Classi Item Content- Concept planning time During implementation planning
fication Target Forecast of the plan Evaluation
Production Cycle time,
Capacity roduction volume
Utilization (%)
Reliability Quality (non-defect
Product rate);
Durability (Years)
Overall
Evalu-
ation
Evalu- A: Above the target; B: Equal to the Target; C: Below the Target
ation
If the overall evaluation result is C, the plan should be worked out again.

TPM Club India
Flowchart of Initial-Phase Production Flow Control

Staff in charge
Time Production Mainten- Planning
Initial-phase production control step
dept. ance Dept. dept.
Consultation/cooperation 1. Equipment that incorporates development factors
2. Continues processing equipment
Before 3. Equipment that requires investment of 10 million or more
4. Equipment that greatly affects production, quality, safety, and cost
equipment
installation Designated report Determination of control targets and the person in charge of control
Designation Plant
Issuing designated notification sheets Form 1 manager
Preparation of an execution plan Indication Form 2

Installation Preparation of Note (1)
Decommis- Control Tables A and B Form 3-1
sioning,and Occurrence of equipment
Survey Preparation and attach-
and quality problems Form 4 should be attached to
Form 3-1 (to be indicated as
Counting, analysis, Form 5; Note (2) BM)
and countermeasures To be execution
once per week
Form 4 should be attached to
Improvement Preparation and attachment Form 3-1 (to be indicated as
of the Control Card CM and PM). Forwarding the
Information
Forwarding an analysis report (to be registered
Form 5; Once/month As A4 information)
Reflection on the next machine
Operation Operation Entry in Control Table B

(production volume, etc.) Form 3-2
Occurrence of equipment
and quality problems Preparation and attach- Form 4 should be attached to
ment of the Control Card Form 3-1 (to be indicated as
Counting..conversion
BM
into graphs
Form 3-2;
To be enforced by the team
Counting, analysis, Leader once per week
and countermeasures
Form 5;
to be execution
Preparation and attach- Form 4 should be attached to
Improvement once per week Form 3-1 (to be indicated as
PM, CM

TPM Club India
Flowchart of Initial-Phase Production Flow Control (Contd)
Forwarding an analysis report Form 5;

Once/month (to be registered
as A4 information)
Reflection in the next machine
Yes
Target attainment
Operation
No
Lifting Yes
is possible
No
Consultation
Alteration Issuance of alteration notifications Form 1
Lifting Issuance of lifting Form 2

notifications Plant
manager
Note (1) Note (2) Note (3)

Form 3-1 Form 3-2 Form 4 Form 5
Initial Phase Production Flow Initial Phase Production Flow Initial-phase production flow control Initial-phase production flow control analysis
Control Table A Control Table B “Initial-phase Management Card” report
Initial Phase Production Flow Date BM, Entry Initial phase production
PM, example control analysis
Control Table A Equipment name Production Equipment downtime CM
Machine Maintenance
Target and changes
volume Frequency ratio

Machine member name Man- Man- Down Stop- Equip- member performance
hours minites time page ment, name
in performance
Min factor quality
Defective pro- Pheno-

duct ratio menon
and
cause
Counter-
measures
(source: Data announced by Yokohama Rubber Co.,Ltd.)

TPM Club India
Collection and Utilization of Technological Information about Product Design
Information Study and processing Design data Design elaboration
Catalogs, patents and Improvement of inquiry

magazines Inquiry specifications
Specifications
Literature
(technological data) Technological Design standards
Design manuals
Data (criteria)
Design calculation sheets
Instruction manuals Collection of expertise
Design review (DR) checklists of drawing check DR for each step

One –shot
FMEA data Drawing check data
Debugging acceptable
Debugging quality start-up;
Common parts lists
Test reports
Utilization of standard Defect-free
Drawing (product)
Improvement proposals Technological Maintenance drawings design;
viability judgment
Study, Information;
Design changes Reliability Easy-to-use
MP information Information
Safety meetings design;
TM sheets Minor defect
countermeasure Easy-to-
Reports; Manufacture
FMEA Recurrence design;
prevention
Complaint information reports MP Design
CAD utilization Automated editing
and design
Equipment capacity and
Processing technology
MP information
Cost reduction about
Information equipment
Market requirements
Common
specifications
Accident reports
Safety measure
Actual confirmation
Sheets Reports

TPM Club India
MARKET SURVEY
MARKET
SURVEY
EXISTING CUSTOMER EXISTING CUSTOMER NEW CUSTOMER NEW CUSTOMER

EXISTING PRODUCT NEW PRODUCT EXISTING PRODUCT NEW PRODUCT

TPM Club India
MARKET SURVEY
E. PRODUCT
N. CUSTOMER
E. PRODUCT N.PRODUCT
E. CUSTOMER N. CUSTOMER
N. PRODUCT
E. CUSTOMER

TPM Club India
MARKET SURVEY
Existing Product / Existing customer means, increasing

the sales volume Of the existing products in the existing
segment of the market. From here, We can get the
Customer complaints, where we need to focus more in the
system itself.
Existing Product / New customer means, we are going to

introduce a Product, which is existing but to the new
segment of market. Here, we Have to address all the
customer related inputs recd from the previous Segment as
well as, points like, easy to use, cost competitiveness etc.,

TPM Club India
MARKET SURVEY
New Product / Existing customer Here, we have to survey

the feasibility of the new product and the attractiveness of
The product.
New Product / New customer means, we are going to

introduce a Product, to the new segment of market. Here,
we Have to address all the customer related inputs recd
from the previous Segment as well as, points like, easy to
use, cost competitiveness etc.,

TPM Club India
MP SHEET

TPM Club India
Collection and Utilization Flow of MP Information

Information sources Obtaining methods Study and processing Accumulation of information Utilization of information
Maintenance Design Common Utilization of

ledgers standards specifications common specifi-
Occurrence of cations
failures and defects
Morning market
Expertise Determination of
Meetings
basic specifications
Manufacturing drawings
Corrective improvement
maintenance reports Preliminary study
Basic equipment
Technological specifications Determination of
study meetings, made-to-order MP
Initial-phase data
survey of machine about equipment MP meetings specifications Designs
capability capability and
accuracy
Conversion into
Instruction manuals drawings
Energy-saving Implementation
activities various kinds of check sheets Use of check sheets
reports
Initial-phase production
Occurrence of
Reports Flow control records
accidents
Initial-phase
DR Dr record tables Decommissioning records production
flow control
MTBF data Technological

data; catalogs Technological data; Catalogs Instruction manuals

TPM Club India

TPM Club India
Information to Autonomous Maintenance

TPM Club India
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TPM Club India

Faculty: TPM Club India

TPM Club India © Confederation of Indian Industry

TPM Club India Page M - 2 © Confederation of Indian Industry

Need for Development Management

• It takes too much time for installation of a new machine

• There are too many troubles while installation

• There is a mismatch on many parameters

• It takes too much time to achieve the rated out put

• It takes more amount of money than the budget

• Sometimes, some of the improvements done have to be repeated

TPM Club India Page M - 3 © Confederation of Indian Industry

Reasons for these problems

• There is no integration between the different

TPM Club India Page M - 4 © Confederation of Indian Industry

NEW MACHINE NEW PRODUCT

TPM Club India Page M - 5 © Confederation of Indian Industry

• To reduce time over run

TPM Club India Page M - 6 © Confederation of Indian Industry

TPM Club India Page M - 7 © Confederation of Indian Industry

The available capacity = 5 machines

TPM Club India Page M - 8 © Confederation of Indian Industry

Need for New Machine

• Increase in production levels

• Too many problems in the existing machine

– Too much breakdowns

– Reliability is too poor

• Producing a completely new product

TPM Club India Page M - 9 © Confederation of Indian Industry

Reliability: Characteristics that do not cause functional decline or stoppages

•Low frequency of failures • Low frequency of minor stoppages

TPM Club India Page M - 10 © Confederation of Indian Industry

Ease of Jishu-Hozen: Characteristics enabling operators to perform

TPM Club India Page M - 11 © Confederation of Indian Industry

Expectations in a machine (Contd)

TPM Club India Page M - 12 © Confederation of Indian Industry

Expectations in a machine (Contd)

TPM Club India Page M - 13 © Confederation of Indian Industry

NEW EQUIPMENT DEVELOPMENT

ENHANCING ADDING NEW

TPM Club India Page M - 14 © Confederation of Indian Industry

ENHANCING EXISTING CAPACITY (a)

TPM Club India Page M - 15 © Confederation of Indian Industry

Loss detail data collection: Sample of a machine

1 Breakdown Minutes 150

2 Setup & Adjustment Minutes 0

3 Tool change Minutes 10

5 Idling & Minor stoppage Minutes 24

6 Speed loss Minutes 0

7 Defect & Rework Minutes 46

8 Shutdown loss Minutes 45

9 Management loss Minutes 20

10 Operating motion loss Minutes 0

11 Line org. loss Minutes 0

12 Logistics loss Minutes 0

13 Measurement and adjustment Minutes 20

14 Cycle time Minutes 2

15 Total down time Minutes 315