Training Objective

Capacity the employees to use the PM Analysis

Methodology where through of study with physical
terms they can eliminate totally the chronic losses

ZERO…
Chronic Losses
 It's very important

Discipline

Team Work

Motivation

Knowledge

Commitment
Agenda 1st day
Agenda 2nd day
Agenda 3rd day
 Chronic & sporadic Losses

Sporadic losses occur suddenly and infrequently,

they result from a single cause that is relatively easy
Fault to identify and solve
Level

Sporadic Losses

Chronic Losses

Chronic losses, on the other hand,

live up to their name by resisting a wide Optimal Conditions
variety of corrective measures.

Time
 P- M Analysis

Single Cause

Varying complex
combinations
One of multiple
varying causes

90-99% of Elimination 100% of Elimination

Conventional method P.M Analysis

 P- M Analysis
Single causes that vary constantly
Suppose for a given problem there are ten potential causes and each time the
problem occurs the cause is different. Some time it may be A, some time C or D
and so on. Consequently, measures focused on only specific cause cannot
control the problem.

Varying combination of causes

In some case a combination of multiple and overlapping causes generates the
problems. To make matters worse, each time the problem occurs, a different
combination of factors may be involve. Today it may be factors A, B and C;
tomorrow A, C, G and H.

Problem in reducing chronic losses

To archive a lasting reduction in chronic losses we must do three things;

 Identify all factors that conceivably contribute to a loss

 Thoroughly investigate each factor
 Eliminate any malfunctions or suboptimal conditions discovered in the process
 Concept

P-M analysis is more than an improvement methodology, it is

a different way of thinking about problem and context in which
they occur.

Mechanism
Phenomenon 4 Ms ( causal factors )
Machine / Material / Man / Method

 Look at phenomenon analytically and systematically

 Review all causal factors

 Identify all abnormalities and reduce them to ZERO

 Tree levels of causal factor

Constituent Condition Primary 4M Correlation Secondary 4M Correlation

1 1-1 1-1-1

Phenomenon
Physical 1-1-2
1-2

1-1-3

2 1-1-4

Unit Level Subassembly Level Component Level

P- M Analysis steps

Step 1 Step 4
Clarify the Phenomenon Study 4Ms for causal factor

Step 2 Step 5
Physical Analysis Set optimal condition
of phenomenon and standards

Step 3 Step 6
Plan and conduct
Identify Constituent Condition a survey of factor

Step 5 Step 7
Set optimal condition Identify abnormalities
and standards to be addressed

Step 6
Plan and conduct
a survey of factor Step 8
Restoration - Improvements
Maintenance Control
Step 7
Identify abnormalities
to be addressed
 Step 1
Breakdown
Clarify the Phenomenon information

OE - Eficiência Global Perdas Internas - Linha 4

OEELinha
line
4 4 Losses Losses by equipment
(GAP)
2001 2002 2001 2002
100
45,0
90 85 85 83 85
82 82 40,0
80 79 80
80 74 74 76 35,0
73 73 73
70 30,0
68 68
70 25,0
61

%
60
58 20,0
60
15,0
10,0
50
%

5,0
40 0,0
Me t a
BM97 BM98 BM9 9 BM0 0 J an Fev Ma r a br mai ju n ago se t out nov de z Jan Fe v Ma r Ab r
02
30 BM 41,6 32,2 20 32 18

Tr oc a insumos 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0
20 Fa lha ope ra ciona l 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,3 0,0 0,0 0,0 0,0 0,0 0,0 0,0

Ad min ist r at ivo 0,1 0,0 0,2 0,2 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,0

10 Ve locida de 0,0 1,6 0,0 2,0 0,0 0,0 0,0 0,0 0,0 0,0 0,1 0,0 0,0 0,0 0,2

De fe it o de qua lid ade 2,3 1,3 1,3 1,4 4,1 0,8 0,3 1,1 0,5 0,7 1,2 1,2 3,4 0,7 1,2

0 Inicio 2,8 0,7 0,8 0,5 1,1 3,8 0,4 4,5 0,8 1,2 0,6 0,7 1,3 0,3 0,5

Limp ez a 7,9 6,9 3,1 4,8 3,4 3,8 2,3 2,8 2,5 2,9 2,7 1,5 1,5 1,6 1,7
set
mar

abr

Abr
out

Fev
jul

Mar
jan

jun

Jan
mai

dez

Meta
ago
fev

nov
BM 97

BM 98

BM 99

BM 00

Me diçã o e a just e 0,0 0,0 0,0 0,0 0,0 8,5 0,9 0,0 3,9 4 ,1 4,6 5,7 6,8 3,1 1,3

Se t up 0,0 0,0 0,2 0,3 0,3 2,4 0,2 0,0 0,0 0,2 0,0 0,0 0,1 0,0 0,0

Data
Losses by subassembly Losses by reason collection
 Step 1
Clarify the Phenomenon
Date Collection

Data Collection Spread Sheet

Phenomena are insufficiently stratified and analyzed

It is all too easy to find plants where defects and failures are not carefully observed
and sufficiently stratified, or broken down into discrete and differing aspects. In failing
to observe the relevant phenomena carefully, people often do not notice the defect
Patterns ( how ), elements ( where ), and periods ( when and how often ) that
characterize them. For example, there are several ways;

 During morning startup

 Before and after blade replacement
 Before and after changeover
 During normal operation
 Step 1
Clarify the
Clarify the Phenomenon Phenomenon

What : What is it happing ? ( what the operation is seeing )

Where: Where is it happing ? ( equipment or component )
When: Any variation related to time or period
Who: Any variation among the people involved in the operation
Which: Is there any characteristic trend over time ?
How: How the situation goes from normal to abnormal condition
How Much: Total of Loss ( money, product, complains, so on )
Write the phenomenon according to following
How - What – Where – When – Which – Who and How Much
 Step 1
Clarify the
Clarify the Phenomenon Phenomenon

What:…..Teared or deformed carton

Where:…In the belt
When:.….During continuous process
Who:.…..Independent of man skill
Which:....No particular operation
How:...…Fallen carton during moving from magazine to belt
How Much: $ 5,000.00 by month of waste

Fallen carton during moving from magazine to belt,

due to deform / teared carton, in the continuous process,
with no particular operation and independent of man skill
 Step 1
Clarify the
Clarify the Phenomenon Phenomenon

60 min
 Step 1
Clarify the
Clarify the Phenomenon Phenomenon

5W-2H
WHAT:…….…...56g roll-on deodorant bottle is too high
WHEN:…….......After placing the cap by the cap spindle
WHERE:……….At the capper
WHO:…………..Does not depend on the operator’s skill
WHICH:………..It tends to raise
HOW:…………..The top cap gets off
HOW MANY:.....1920 bottles with poorly screwed caps in one shift

Phenomenon
56g roll-on deodorant bottle cap is too high
after the cap is placed by the cap spindle on the
capper. This happens randomly, regardless of
the operator’s skill, and it occurred in 1920 bottles
with poorly screwed caps in one production shift.
 Step 2
Physical Analysis
of phenomenon
Physical Analysis

Think visually
Some people may feel ill-equipped to express themselves in technical terms, but physical
analysis does not require fancy words or complicated expressions. In fact, such words
would only obscure the phenomenon. The best and simplest approach is to think visualy.
Consider drawing of how product and equipment elements interact to bring about the
defect or functional failure.

Key Steps in Physical Analysis

1- Identify operating principles: Review machine diagrams and manuals to understand
the equipment basic operating principles.

2- Identify operating standards: Learn the functions and mechanisms of equipment and
Devices by sketching simple machine diagrams.

3- Identify interacting elements: Draw contact diagrams to identify what relationships

define the phenomenon.

4- Quantify the physical change involved: Identify appropriate physical quantities and
change in those quantities.

5- ABCD Methodology: help us to write the phenomenon

 Step 2
Physical Analysis
of phenomenon
Physical Analysis

The importance of understanding the mechanisms and its functions

Understanding the mechanisms and structure of the equipment involved is important as
defining the phenomenon. Intimate Knowledge of equipment helps clarify what happens
to produce particular malfunctions or defects. Mechanisms means a group of equipment
elements with a single function and how it functions. Structure refers to how all the
equipment elements are put together or assembled

Key Steps for understand them

1- Draw the process flow

2- Draw the equipment mechanisms

3- Use materials to facility the comprehension , such as; technical manuals, pictures
drawings so on…

4- Make OPL to multiply the knowledge

 Step 2
Physical Analysis
of phenomenon
Physical Analysis

Process flow and mechanism

P L C

O s fra s c o s q u e v e m a tra v é s d o tra n s p o r ta d o r D u ra n te a p a ss a g e m d o fra s c o n a e s t re la O f r a s c o é t r a n s f e r id o a t r a v é s d a e s t r e la d e

s ã o t r a n s f e r id o s a t r a v é s d a r o s c a s e m f im d e e n tra d a , o s e n s o r d e te c ta a s u a p re s e n ç a e n t r a d a p a r a a e n c h e d o r a , q u e é p o s ic io n a d o
( v e r m e ) p a r a a e s t r e la d e e n t r a d a d a e n v ia n d o u m s in a l te m p o r iz a d o s o b b ic o d e e n v a s e o n d e d á - s e in ic io a z o n a d e
e n c h e d o ra p a ra o P L C c o m a n d a r o e n c h im e n t o e n c h im e n t o

P L C V á lv u la d ir e c io n a l M A C

N o p r o c e s s o d e e n c h im e n t o . .. . . . a t r a v é s d o s in a l e m it id o p e lo . . . f a z - s e a in v e r s ã o d a v á lv u la
P L C ... d ir e c io n a l ( M a c ) . . .

H a s te o b tu ra d o ra H a s te o b tu r a d o r a
M e d id o r d e V a z ã o
B ic o d e e n c h im e n to
V ia A V ia A
V ia B V ia B
P ro d u to P ro d u to

A t r a v é s d o m e d id o r d e v a z ã o ( f lo w m e t t e r ) , é f e it o
H a s te o b tu ra d o ra H a s te o b tu ra d o ra a m e d iç ã o d e p u ls o s p o r m ililit r o p r o g r a m a d o
“fe c h a d a ” “a b e r ta ” n o p a in e l d e o p e r a ç ã o p a r a o e n c h im e n t o d o f r a s c o

...e c o m u m a p r e s s ã o d e “ 4 , 5 b a r ” , é f e it a a in v e r s ã o d e a r c o m p r im id o d a v ia “ A ” p a r a a v ia “ B ” ,
a c io n a n d o a h a s t e o b t u r a d o r a lib e r a n d o a p a s s a g e m d e m a s s a ( p r o d u t o ) ,
p a r a o f r a s c o p r e v ia m e n t e p o s ic io n a d o e m b a ix o d o b ic o d e e n c h im e n t o

A p ó s o t é r m in o d o e n c h im e n t o u m s e n s o r c a p a c it iv o O s fra s c o s s a e m d a e n c h e d o ra e
v e r if ic a a p r e s e n ç a d e lí q u id o n o f r a s c o , s ã o tra n s f e r id o s p e la e s t r e la d e s a í d a M e d id o r d e V a z ã o
f a z e n d o a r e je iç ã o , c a s o o v o lu m e e s t e ja f o r a p a ra a ta m p a d o ra o n d e
d o p r o g r a m a d o p e lo P L C . in ic ia - s e o p ro c e s s o d e ta m p a m e n to
 Step 2
Physical Analysis
of phenomenon
Physical Analysis

Mechanism ofDOPhenomenon
MECANISMO FENÔMENO

Filling Process
Processo de envase Condição
NormalIdeal
Filler Machine
ENCHEDORA após envase
Situation

Head Space 16 ml

Processo de envase
Filling Process Condição Atual
Filler Machine Abnormal
ENCHEDORA após envase
Situation

Transbordamento
Level out
de massa pelo frasco

of ideal
 Step 2
Physical Analysis
of phenomenon
Physical Analysis

Study, understand the working of system and mechanism

Analyze the phenomenon in physical term, it means, use physical principle to

define the relationship the contact point between equipment and product.

A- B - C- D methodology
A- Physical dimension involved ( pressure; vacuum, temperature; distance, so on )

B- Variation of dimension physical ( increase, decrease, high, low, so on )

C- Product ( box, carton, bottle, so on)

D- Component (guide, belt, so on )

Sequence of phenomenon description:

B–A -C-D
 Step 2
Physical Analysis
of phenomenon
Physical Analysis

Match doesn’t light

Potassium permanganate

Matchstick is moist
Tip of matchstick is too small
Match tip is worn down
Match is struck with insufficient force
MATCH Match is struck at incorrect angle

Potential
causes

Physical Phenomenon

The match doesn’t ignite because friction heat insufficient

 Step 2
Physical Analysis
of phenomenon
Physical Analysis

Bicycle brakes function poorly

Rubber brake pads are worn

Bubber brake pads do not meet the wheel at proper angle
Rubber brakes pads are contaminated with oil and dirt
Brake cable is extended
Physical Phenomenon

Potential causes Due to insufficient friction resistance, the brakes

do not provide enough torque to control the
bicycle´s speed
 Step 2
Physical Analysis
of phenomenon
Physical Analysis

Variability of piece's diameter

C D Grindstone
A
A- B - C –D methodology
B = variations
A – Physical dimension involved ( pressure; temperature; distance etc... )

B- Physical variation ( decrease, increase, high, low, so on )

C- Product ( box, carton, bottle etc...)

piece D- Component (guide, belt, grindstone so on )

Phenomenon
Variation ( B ) of distance ( A )
between piece rotation center ( C )
grindstone surface ( D )
 Step 2
Physical Analysis
of phenomenon
Physical Analysis
Variation in the pitch per rotation as the flyer winds the
copper wire around the bobbin
A- B - C –D methodology
Flyer D bobbin
A - Physical dimension involved ( pressure; temperature; so on )

B- Physical variation ( decrease, increase, high, low etc... )

C- Product ( box, carton, bottle etc...)

D- Component (guide, belt, grindstone so on )

Rotation

C Phenomenon
Copper wire Variation in pitch ( lateral distance )
per rotation as flyer winds copper wire
Transverse motion around bobbin

A
B = Variation ( step )
 Step 2
Physical Analysis
of phenomenon
Physical Analysis

Failure during carton forming

 Step 2
Physical Analysis
of phenomenon
Physical Analysis

Falha
Failure
naduring
armação
carton
de cartucho
forming
 Step 2
Physical Analysis
of phenomenon
Physical Analysis

Failure during carton forming

 Step 2
Physical Analysis
of phenomenon
Physical Analysis

Failure during carton forming

 Step 2
Physical Analysis
of phenomenon
Physical Analysis

Failure during carton forming

 Step 2
Physical Analysis
of phenomenon
Physical Analysis

Failure during carton forming

 Step 2
Physical Analysis
of phenomenon
Physical Analysis

Failure during carton forming

 Step 2
Physical Analysis
of phenomenon
Physical Analysis

Failure during carton forming

 Step 2
Physical Analysis
of phenomenon
Physical Analysis

Failure during carton forming

 Step 2
Physical Analysis
of phenomenon
Physical Analysis

Failure during carton forming

 Step 2
Physical Analysis
of phenomenon
Physical Analysis

Failure during carton forming

 Step 2
Physical Analysis
of phenomenon
Physical Analysis

Failure during carton forming spacer ( piece )

D
B= variation

C A - Distance

Carton B - Variation
2nd folder C - 2° fold

D - Spacer

Phenomenon
Variation (B) of distance (A) between 2nd carton folder ( C )
and the spacer ( D ) during moving of carton to conveyer
 Step 2
Physical Analysis
of phenomenon
Physical Analysis

80 min
 Step 2
Physical Analysis
of phenomenon
Physical Analysis

Step 1 - Phenomena

56g roll-on deodorant bottle cap is too high

after the cap is placed by the cap spindle on the
capper. This happens randomly, regardless of
the operator’s skill, and it occurred in 1920 bottles
with poorly screwed caps in one production shift.

Step 2 Physical Analysis through the working mechanism of the phenomenon

Ideal Condition
Capper
Bottle
with cap

A Centralization Beginning End of

of capping capping

B Variation in centralization during cap screwing

process process

Cap Cap conveyor

C Cap spindle starwheel

D Bottle neck Capper Current condition Bottle with

Summary of the mechanism C poorly

screwed cap

Variation in centralization B Beginning End of

D of capping

during cap screwing, between

capping
process process

the cap spindle and the bottle neck A Cap Cap conveyor
starwheel

Tampa mal rosqueada

 Step 3 Procedure for checking
Constituent Conditions Constituent Conditions
- The steps shown in table bellow are helpful when checking each of the 4Ms to see
whether off-standard conditions may be linked to defect phenomenon. The table
provides a simple example of approach.
Passo De scrição

1 - Identify equipme nt Identify the functional units which constitute the

mecha nism equipment

2 - Understand how me chanism Examine each mechanism and identify the role it plays
fuction togethe r in relation to the equipment as a whole

3 - Conside r the cause a nd

Checks for links with abnormal phenomena when any
effe ct rela tionship be tw ee n
mechanism, subassembly, or component falls to play
mecha nisms and a bnorma l
its expected role
phe name na

Investigate links between the appearance of abnormal

4 - Identify constitue nt
phenomena and the condition of mechanisms
equipme nt conditions
potentially connected to such phenomena

Even if equipment mechanism are fulfilling their

5 - Identify constitue nt
expected roles, check to see if abnormal phenomena
conditions re late d to sta ndards
appear when; A - designated standards are too lax or
and to pe ople cha rge d w ith
inadequate. B- people charged with adhering to those
adhe ring to the m
standards are not doing so

Even if conditions involving the equipment, standards,

6 - Identify cosntitue nt
and people's adherence are all in order, check for
conditions re late d to the quality
phisical defect phenomena resulting from quality defects
of pre vious processes
in incoming material
 Step 3 Identify and understand
Constituent Conditions the system and mechanisms

3.2

1.0- Conveyor
2.0- In Star of bottle
3.1
3.0- Filler subassembly
3 3.1- Valve
3.2- Flow meter
3.3
3.3- Nose

4 4.0- Out star

2
1 5.0- PLC

5
 Step 3 Identify and understand
Constituent Conditions the system and mechanisms
 Step 3 Identify and understand
Constituent Conditions the system and mechanisms

Variation in the stop point

Screw conveyor – Variation in the space of bollte

Responsible to keep
the ideal space between
the bottle and move
them in the correct position
in the star ( in )

System Constituent condition

 Step 3 Identify and understand
Constituent Conditions the system and mechanisms

Failure during forming carton

2 – Vacuum System Variation in vacuum

Move the carton to conveyor pressure in the suckers

Variation in the stop position

( catch and release ) of sucker arm

System Constituent condition

Steps 5. 6 and 7

Step 5
Set optimal condition
and standards

- Establish the optimal conditions

Step 6
Plan and conduct
a survey of factor

- Develop measuring method

- Make the measuring

Step 7
Identify abnormalities
to be addressed

- Compare the measuring with optimal condition

- Identify abnormalities
 Step 5 Step 6 Step 7
Set optimal condition Plan and conduct Identify abnormalities
and standards a survey of factor to be addressed

Failure during forming carton

2 – Vacuum System Variation in vacuum NOK

pressure in the suckers
Move the carton to conveyor SV = 480 + - 10 mm Hg

RV= 330 + - 5 mm Hg

Variation in the stop position

( catch and release ) of sucker arm

Catch Release
SV = 90° + - 1 SV = 4° + - 1

RV= 82° + -3 RV= 15° + - 3

NOK

System Constituent condition

 Step 3 Identify and understand
Constituent Conditions the system and mechanisms

90 min
 Step 4 Study 4Ms for
Study 4Ms for causal factor causal factors

- List and investigate any correlation between the constituent condition identified in the previous
step and the basic production inputs or 4Ms ( equipment, people, materials, methods ). Put another
way, this means identifying cause-and-effect relationships between constituent condition specific
and 4M elements. The constituent condition becomes the effect and we review 4Ms elements for
potential causes. Identify all logically conceivable elements necessary to generate the constituent
conditions.
 Step 4 Study 4Ms for
Study 4Ms for causal factor causal factors

Constituent Condition Primary 4M Correlation Secondary 4M Correlation

Variation in vacuum
pressure in the suckers
Valve blocked
Variation of load loss ( vacuum )
between enter tube and suckers
Tube between valve
and filter blocked

SV = 480 + - 10 mm Hg Leaking in the tube connections

RV = 330 + - 5 mm Hg
Leaking on filter cap

NOK Filter dirty

Variation of vacuum pressure Tube between filter and moving

in the main supply tube arm blocked
 Step 5 Step 6 Step 7
Set optimal condition Plan and conduct Identify abnormalities
and standards a survey of factor to be addressed

Constituent Condition Primary 4M Correlation Secondary 4M Correlation

Valve blocked
Variation of load loss ( vacuum )
Variation in vacuum between enter tube and sukers
pressure in the suckers Tube between valve
and filter blocked
SV 30 + - 3mm Hg
SV = 480 + - 10 mm Hg Leaking in the tube connections
RV 232 + - 10 mm Hg
RV = 330 + - 5 mm Hg
NOK Leaking on filter cap .

NOK Filter dirty

Variation of vacuum pressure Tube between filter and moving

in the main supply tube arm blocked
 Step 4 Study 4Ms for
Study 4Ms for causal factor causal factors

120 min
 Step 8
Restoration - Improvements
Maintenance Control

- Propose and Make Improvements

- In this eighth and final P-M Analysis step, teams propose make any
correlations and improvements required for each abnormality, then plan and
institute appropriate preventive measures.

Corrective Action Plan

Preventive Action Plan

Maintenance Plan
 Step 8
Restoration - Improvements
Maintenance Control

Review the operational Procedures

Review the cleaning procedures

Review the inspection procedures

Training for changes

Record the improvement

Review the Skill Matrix

Make OPL
Preparing Activity Board

60 min