PM Analysis in Maintenance Management

1. Maintenance Management
Phenomenon & Mechanism Analysis
Presented to : Mr. Amit Phogat By : Bittu
Singh
Asst. Professor Radhe
Kumar
NIFT-Gandhinagar Shubham
Singh

2. THE TERMITES OF PRODUCTION –
CHRONIC LOSSES
 Chronic Losses – caused by gradual
machine deterioration, but not potent
enough to critically damage machine
in a single occurrence
 Machines are run at slower pace –
avoid breakdown – continual under-
performance
 Becomes the “Cost of doing Business”
– part of the status quo
 Japanese TPM texts – Chronic losses
always account for higher percent
than sporadic losses
Image retrieved from : https://leanmanufacturing.online/losses-costs-
efficiency/
Combination
of factors :
Chronic
Losses
Cause
Cause
Cause
Cause

3. P-M ANALYSIS : INTRODUCTION
 Developed by Kunio Shiroshe of Japan Institute of Plant Maintenance
 Physically analyses chronic losses according to inherent principles and
natural laws that govern them
 Clarifies the mechanics of their occurrence, and conditions that must be
controlled to prevent them
 Refined variation of Fishbone diagram
 Sequence : Physically analyse chronic problems, Define conditions
underlying abnormal phenomena, Identify factors contributing to
phenomena
Phenomena –
Deviations from
normal to
abnormal state
Physical –
Analysis to
understand the
principles
behind an
abnormal event
P Understand
mechanics of the
problem of abnormal
phenomena – How
they are produced;
Understand the
mechanism of the
equipmentsUnderstand the
relations between
the abnormal
event & the 4
production inputs
(4 M’s) – Machine,
Man, Material,
Method
M

4. WHEN TO USE P-M ANALYSIS ?
Root Cause Analysis
5-Why Analysis
Singl
e
Caus
e
Multiple
Cause
s
Chronic
Losses
Complex combination
of causes
Bar chart retrieved from : https://leanmanufacturing.online/p-m-analysis-basic/

5. PM Analysis Vs. Conventional Approach
Approach Conventional
Approach
P-M Analysis
Objective Reduce defects to ½ or
1/3 of their present level
Reduce defects to zero
or get as close as
possible
Concepts • Priority based
• Focus on factor having
greatest impact
• Carry out measures
only
on selected factors.
• Not priority-based
• Think logically; list all
possible factors behind
defects
• Investigate all factors
• Correct all
abnormalities
Methodology Cause-and-effect-
diagram
PM Analysis
Application • Use where defect rate • Use where defect rate

6. P-M Analysis Steps
1. Clarify the phenomenon
2. Conduct a physical analysis
3. Define the phenomenon’s constituent conditions
4. Study production input correlations (4Ms)
5. Set optimal conditions (standard values)
6. Survey casual factors for abnormalities
7. Determining abnormalities to be addressed
8. Propose and make improvements

7. 1. Clarify the phenomenon
 ‘Phenomenon’ means an occurrence or fact that
can be observed.
 In P-M analysis “clarifying the phenomenon”
means using our observation skills to grasp facts
and illuminate underlying concepts.
 Carefully define and categorize the abnormal
occurrence.
 Without this, P-M analysis may end up missing
the mark.

8. 2. Conduct a physical analysis
 Physical analysis is a logical investigation of
phenomena such as defects or breakdowns that
explains how the phenomena occur in terms
physical principles and quantities.
 Physical analysis explains properly stratified
phenomena from a physical point of view.
 Determines the phenomenon in physical term,
e.g., how the parts or process conditions change
in relation to each other to produce the defect or
failure.

9. 3. Identify constituent conditions
 Identify all the conditions that will consistently produce the
phenomenon.
 It is to review all the conditions that consistently give rise to
the problem.
 These are constituent conditions either necessary or
sufficient for the physical phenomenon analyzed in the
previous step to occur.
 Any constituent condition fall into one of the four categories of
production inputs:
(1) Machine
(2) Man
(3) Material
(4) Methods

10. 4. Study 4Ms for causal factors
 Look for potential cause-and-effect relations between the
constituent conditions and equipment, materials, work
methods, and human factors.
 The constituent condition becomes the “effect,” and review
4M elements for potential “cause”.
 4Ms are further divided into primary 4Ms and secondary
4Ms.
Phenomenon Constituent
Conditions
Primary 4Ms Secondary 4Ms
1. A car engine will not
start.
1. Gasoline is not
supplied to the
engine.
1-1. the fuel system is
without gasoline.
1-1-1. The gasket
between the gas tank
and the fuel line is
worn.
1-1-2. The gas tank is
empty.
2. Electrical power is
not supplied to the
engine.
2-1. The battery is
without power.
2-1-1. A battery cable
is loose.
2-1-2. the battery is
dead

11. 5. Establish optimal conditions(standard
values)
 Review the equipment’s current precision
levels to determine where new or revised
standards are deficient.
 Seek out and identify all abnormalities within
the factors.

12. 6. Survey causal factors and
abnormalities
 Determine the most reliable, efficient ways to measure
the gap between the condition of causal factors
identified in step 3 and 4 and their ideas value
confirmed in step 5.
 Determine the most efficient way to physical survey all
the factors at the machine location.
 Conduct the survey, measuring targeted values and
comparing them to optimal standards to determine
which factors contain abnormalities and thus are
actual causes of defect phenomenon.

13. 7. Determine abnormalities to be
addressed
 Review survey results and list all abnormalities to
be addressed.
 Key to identifying abnormalities:
1. Thoroughly investigate all factors.
2. Compare normal conditions against current
standards.
3. Think in term of optimal conditions, not just
necessary conditions.
4. Understand the causal factors behind each
condition classified as abnormal.

14. 8. Propose and make
improvements
 Final P-M analysis step.
 Team propose and make any corrections and
improvements required for each abnormality,
then plan and institute appropriate preventive
measures.
 Preventive maintenance procedures to
maintain optimal condition.

15. P-M analysis is unsuccessful
when…
 Some factors are overlooked.
 Abnormalities are not thoroughly identified.
 Accepted standard values are incorrect or
inappropriate.
 Measurement methods are incorrect or
inappropriate.
 The counter measures themselves contain
errors.

16. P-M ANALYSIS : SUMMARY
Step 1 Classification of the
phenomenon
Perform sufficient
stratified
Step 2 Physical analysis of
phenomenon
Analysis the view point of
physical for phenomena
Step 3 Conditions to reproduce
phenomenon
Study the condition under
which phenomenon can
be reproduced
Step 4 Relevant equipment,
tooling, materials,
methods
Study relevant equipment,
tooling, material, way
Step 5 Study on research
methods
Study the range of
research, methods of
research and
measurement methods
Step 6 Extraction of the problem Creating standard and
measurement
Step 7 Planning of measure Measures for each
problem

17. EXAMPLE 1 :
ANALYSIS OF COMPONENTS TO ASSESS CAUSES OF THE
FAILURE
Phenomen
a
Point of view Condition as
method
Relation to
the 4M
Relation to the 4M
secondary
Air does not
come until
the needle
• Low air pressure
• Air hose is long
• Broken air hose
Leaking air
in the
cylinder
• Scratches of the
piston rod, wear
Resistance
between the
cover and
piston rod
• Deformation of the
piston rod, scratches
rust
• Deformation of the rod
cover
• Lack of lubrication
Resistance
between the
piston rod
and cylinder
• Deformation of the
cylinder tube,
scratches rust
• Lack of lubrication
Stopinthemiddleof
pistonrodoftheair
cylinder
Resistanceforcereceived
bytherodthantherodis
greateradvance
Driving
force of
the rod is
less
Resistance
experience
d by a
large rod

18. EXAMPLE 2 : P-M ANALYSIS TABLE
Turbine shaft Occurrence and
frequency
By theory and by
drawing to analyse
the phenomena
Machine No. Failure occurs and
sometimes non-
standard for large
ellipse in the
process
Changing the
distance b/w the
centre of the
grinding wheel and
the work piece
NC cylindrical
grinder
Established
conditions
Relevance of the
methods and
materials, equipment
and tooling
Secon
d
investi
gation
Item
(drawing)
Second
item
(part
Position
changes
the
centre of
the
Loose
measure
ment
during
clampin
N
G
N
G
-1 wear
n/d clamp
1-1-2 wear
cam
….
….
1-1-5
NG
NG
NG
NG
OK
Exchang
e
Exchang
e
Exchang
e
Exchang
e
Ok
Ok
Ok
Ok
Measur
es
Sectio
nResult
Thefirstsurvey
items
Toleranc
e
Less0.002
mmImpac
t
Hig
h
Measured0.001mm
Survey
results
Looseness
ofthe
clamp
Judgeme
nt
Judgeme
nt

19. REFERENCES
 Terry Wireman Blog Series. Chronic vs. Sporadic Failure. Retrieved
from : SAP Partner - VestaPartners.com
 Kunio S., Kaneda M. & Kimura Y. P-M Analysis : An Advanced Step
In TPM Implementation. What is P-M Analysis? Page 18. CRC
Press. Retrieved from : Google Books
 Willmott P. & McCarthy D. TPM : A Route to World Class
Manufacturing. P-M Analysis. Page 104. Newnes Publishers.
Retrieved from : Google Books
 P-M Analysis Basics. Retrieved from : LeanManufacturing.online
 Arai K. TPM for the Lean Factory. Phenomenon, Mechanisms &
Causes. Page 3-33. Routledge Publishers. Retrieved from : Google
Books
 Monma H. PM Analysis. 4 March, 2015. Retrieved from : Japanese
Gemba Kaizen Web

20. Thank You!