PILLAR

Initial Control

or

Development Management

DM - 1
 95%
100%
85%
Detailed design and development

75%
Composition of Life Cycle Cost

66%
System analysis, evaluation of substitute plan (trade off),
system decision, and others

50%
Market analysis, feasibility study, operational requirements, concept of maintenance,
and other

25%

0%

Production,
Product planning and Detailed design and System/Product usage
Initial system design construction and
concept design development and logistical support
evaluation

© JIPM, 1987

Fig. VII-3 Jobs Affecting Life Cycle Cost

DM - 2
 Cost of purchases (R&D,
Production

Training Cost
Test, Support and
Equipment Cost
Service (Personnel) Cost

Facility and Equipment

Cost
Logistical Support and Cost Transport and Handling
(Supplies, Transport Cost

Technical Information Cost

Replacement and Scrap Cost

© JIPM, 1987

Concept of Life Cycle Cost

DM - 3
 Equipment Management flow
Equipment management

Autonomous Lubrication Breakdown Preventive Management of

maintenance management maintenance maintenance spare parts

Management
Clean-up Criteria of criteria
inspection Sporadic failure periodical
Lubrication inspection and Rack for
standard servicing replacement parts
Restoration
work Detection of
Detection of malfunctions Use
malfunctions
Request for Failure record Construction plan Confirmation of
Attaching the repair
inventory
tags
Ordering
Detaching the Failure Inspection
tags analysis record
Delivery
Countermeasures
Recording Acceptance test
to prevent the
YES
recurrence of
Education failure Return the materials
MP Information

Reflection into the initial flow management

Establishment of initial flow management

DM - 4
 MP Information Collect and Utilization Flow Chart
Study and Accumulation of Application of
Source of Information Means to gather
process information information

Utilization of
Failure record Design Common common general
Occurrence standar general specification
of failure or d specification

Review and Study Meeting, MP meeting

defects Meeting Preparation of
basic specification
Know-how
Preliminary
Corrective Improvement study
maintenance report Preparation of drawings

MP design
Preparation of
Equipment basic order specification
Investigation of Equipment Specification
capacity, Preparation of
machine
Accuracy of Instruction manual drawings
capacity
initial data Utilization of
Various types of check check sheets
Energy saving Implementatio sheets
activities n report Initial flow
Recording initial flow management
management
Occurrence Accident report Instruction
of accident Manual
Record of trial run
Technical
information Technical data, Catalogs
catalog

DM - 5
 MP Information Points
Fundamental
Definition
characteristics
Reliability Characteristics which prevents
functional depression or stoppage
Maintainability Characteristic which shows easiness
in measuring the deterioration and
restoration of deterioration
Autonomous Characteristics which allows to
Maintainability perform quickest and simplest
cleaning, lubrication and inspection
operation by the operation department
people
Operability Characteristics which allows quick and • Easiness of set-up and adjustment
positive appropriate operation at the • Easiness of tool and grinding wheel exchange and
time of set-up or die change
Energy Saving Characteristics which shows efficient
utilization of resources such as
energy, tools, grinding wheel, oil and
grease which are necessary for
operation of facility
Safety Characteristics which does not cause
direct or indirect injury to human being
Specific Description
• Low frequency of failure occurrence
• Low frequency of minor-stoppage
• Low frequency of defect occurrence
• Quick detection of failure or defects
• Easiness of parts replacement and shortest
confirmation time for restoring the function
• Easiness of cleaning, lubrication and inspection
• Easiness of collecting the chips
• Degree of localizing the source of splashing
their adjustment
• Low unit consumption of resources and energy
• Low frequency of extra works such as response or
handling of failure, minor stoppage, quality loss
etc.
• Fewer rotating and driving equipment exposed to
the operator
• Low frequency of adjustment
• Stability of machine operation cycle
• Easy to conduct static and dynamic
accuracy measurements
• Quick detection of deterioration
• Easy application of lubrication of
replenishing
• Easy performance of overhaul
• Easiness of confirming of lubrication at
terminals
• Easiness of quality maintenance (Easy
measurement of accuracy)
• Easiness of bottom operation (Height,
layout, number, shape, color etc.)
• Easiness of transportation and installation
• Degree of recycling of the resources
• Fewer projects of obstacles
• Good retractability
DM - 6
 MP Design in 7 Steps
Step 1
Product Concept Planning – Select optimal production system
1) Early planning in product development
2) Review equipment investment plan (purpose, investment effects, time limit, etc.) and clarification of requirements to be planned.
3) Compare and evaluate several plans and select an optimal plan……… 1st DR(Design review)

Step 2
Planning – Set production system design goals and frame specification conceptual plan
1) Clarify production system design goal values and equipment specification concepts
2nd DR
2) Evaluate design specification concept (Process FMEA, DP matrix, 3M Conditions, etc.)…
Step 3
Design – Realize design goal values
1) Perform basic design and frame a working budget
2) Evaluate basic design based on equipment specification concept……… 3rd DR
3) Detailed design based on basic design
4th DR
4) Evaluate detailed design.(Part FMEA, MP information, design standards, standards, etc.)

Step 4 Production – Secure production reliability

1) Check reliability of produced parts. (dimensions, materials, functions and performances of purchased parts, etc.)
2) Check of fitting precision (Criteria, standard and MP information etc.)

Step 5
Test run with witness – Evaluation with witness and loaded test run
1) Perform attendance inspection, restore problems to Step 4 and identify more “Fuguai”
2) Evaluation by loaded test run and correct “Fuguai”. (Equipment capability, process capability etc.)
3) Inspection based on specification, MP information, criteria and standards. (by check sheet)

Step 6 Installation test run – secure installation reliability and evaluate test manufacture

1) Measures for enhanced installation reliability. (work schedule, foundation, piping, power and collation with drawings)
2) Evaluate test manufacture by installation test run. (design goal values, specifications, check sheets etc.)

Step 7
Initial flow control. Evaluate and release initial flow control items (minimum run-up time)

1) Implement till production system design goal values are accomplished 100% lead by operation department.
(The point is to debug “ Fuguai” before hand.)
2) Planning design production, maintenance and operation departments are working in unison
3) “Fuguai” is improved till goals are accomplished and is fed back as MP information © JIPM, 1993

DM - 7