Processing point analyze

1
 Index

Chapter 1
Processing point & System diagram
（ Creating a System diagram ）
Chapter 2
Concept of processing point analysis
（Risk assessment, Condition setting）

Chapter 3
Concept of processing point analysis
(Deployment to process stabilization)
- Facility&Equipment inspection standard,
- QM Matrix
2
 Processing point analyze

Chapter 1.
Processing point & System diagram

3
Processing point

4
 What is “Processing point”?

Generally, “Processing” mean

“modify, alteration , disassembly , assembly”
to material/parts by Man or Equipment.

5
What is “Processing point”?

In Definition of “JIPM”,
It mean Contact point between “Work” and “Tool”.

In General Manufacture, Including point below.

Contact point between “Work” and “Work”.
Contact point between “Work” and “Worked material”.
#Importance point is "Is not generated the variation" in the
continuous processing.

6
 Example of “Processing point”
【 Function of drilling machine
： Proper drilling to material 】

■ What is processed  Work

■ Thing to processed
Equipment,Tool  Tool
Material Worked material

In example of left picture,…

①Work ・・・ SUS plate

Oil ②Tool ・・・ Drill
③Worked material ・・・ Oil
In this situation, Processing point is contact
Drill
point between “SUS Plate” and “Drill”.

SUS plate 7
 Example of Processing point (Packaging)
Work (What is processed)
【CAN Transfer process by
conveyor】 CAN (A, B)
Sensor
Tool(Thing to Processed(Equipment,Tool))
GuideA GuideB Guide A & B
Top chain A & B
Flame, Bolt, Nut
Flame, Bolt, Nut, etc..
CAN CAN
A B
Worked material(Thing to processed
(Material))
Lubricant Lubricant conveyor
What is processing point of CAN A ?
Top chain A Topchain B
Rail etc. CAN-A & Guide A
CAN-A & Top chain A
CAN-A & Lubricant
CAN-A & CAN-B

8
System diagram

9
 Structure of System diagram

Object and System for

functions of the forming a Process A Tool
equipment processing point Work

Worked material

Condition

Process B

System to
position the Switching device・・・
processing point

System to maintain
Electricity, Air, Hydraulic pressure ・・・
the continuity of
the processing point

10
 System for forming a processing point

System for constructing/forming a required machine

element to build proper process.

Organize necessary process that maintain object & function of equipment.

Sort process configuration

Tool, Work, Worked material, Condition…

List up all the components used in the system

Make decision to inspection method of mechanical elements for maintain

the system.
11
 System to position the processing point

System for meet the necessary positioning

condition to part processing.

e.g. Switching system for Transfer, Angle, Temp, Weight

・Change over system

・Temp control system
Quantification of positioning

Make decision to inspection method of mechanical elements for maintain the

system.

12
System to maintain the continuity of the processing
point

System for maintain continuous production

in processing of position and form.

e.g. Electricity , Air, …. Utility supply system

create a state that can be continuously maintained stably

Make decision to inspection method of mechanical elements for maintain

the system.

13
 What is process ?

Object and System for

Process
functions of the forming a Process A Tool
equipment processing point Work

Worked material
"Process" mean procedure/each step Condition
of processing (business).
separating each function or object in each facility/equipment. Process B
e.g. in filling machine, separate to process infeed , filling , outfeed.

System to
position the Switching device・・・
processing point
Procedure of filling "Process" should
follow to order of process.System to maintain
Electricity, Air, Hydraulic pressure ・・・
(For prevent lack of fill out
theevery process)
continuity of
the processing point

14
 What is series ?

Object and System for

functions of the forming a Process A Series
Tool
equipment processing point Work

Worked material

Condition

Process B

System to
position the Switching device・・・
processing point

System to maintain
Electricity, Air, Hydraulic pressure ・・・
the continuity of
the processing point

15
 What is “Unit” / “Sub unit” ?
Example of Unit/Sub unit/parts
Unit Sub unit Parts

Air filtration unit Filter Body

Element
Regulator
O ring

・
Lubricator ・
・
Unit・・・
One unit that make up the whole.
Structural units that can be present by itself to be divided.
Sub unit・・・
Structural unit can be split further than unit.
Parts・・・
Parts form a part of mechanism and the instrument.
16
 Example of System diagram (Bottle rinser)
Process Series
Object and
functions of the System for forming
Infeed
a processing point
equipment
Upside down
Tool
Rinsing of surface of bottle
bottle Work
Outer wash
Inner wash Worked material

Draining Condition

Uplight bottle
Outfeed
System to position
the processing Switching device・・・
point

System to maintain
the continuity of Water supply, Air, Hydraulic, Electricity・・・
the processing
point 17
 Example of System diagram (Bottle rinser)
Unit (Sub unit) Parts
System for forming a Upside Tool Ferry plate Fixed bolt
processing point down ・
・
・

Infeed starwheel Plate starwheel

・
・
・

Main guide Guide rail

・
・
・

Gripper Holder
・
・ Lever gripper
・
・
・
・

Work Bottle Spec±・・

Worked
洗浄水ﾞ
Rinsing water RO water
material

Condition Clearance between bottle and guide

Timing between bottle and Gripper

・
・
・
System to position
Switching device Lifting drive motor
the processing point
Encoder for body machine height
System to maintain
the continuity of the Rinsing water supply unit Regulator, Distributer, Strainer・・・ 18
processing point
Utilization of system diagram

19
 Utilization of system diagram
<Aim> : Correctly understanding the machine structure.
And, list 【対象範囲】 機械： XXXXからXXXXまで
up maintenance inspection point that not lack. 【Check point】
電気： XXXXからXXXXまで

Joint
Oil
Air
Drive
Elect.
XXXX System for forming a Process ① Tool Parts A ●
processing point
Work Parts B ●

Worked material Parts C ● ●

Condition Parts D ● ●

Parts E ●

Parts F ● ●

Parts G ●
Process ②
Parts H ●

System to position the Parts I ●

Process ①
processing point
Parts J ● ● ●
Process ②
Parts K ●

System to maintain the ・ ・

Process ① ・
・
・
・
continuity of the
processing point
Process ② 20
 Utilization of system diagram
# Reliability
<Aim>: Visualization of maintainability defect. #Serviceability

【Check point】 【 Maintainability 】 【加工点】

XXXX System Diagram

Joint
Oil
Air
Drive
Electric

Reliabil
Service
Cost

ﾜｰｸ1
ﾜｰｸ2
ﾜｰｸ3
XXXX System for forming a Process① Tool Parts A ●
processing point
Work Parts B ●

Worked material Parts C ● ● ● ●

Condition Parts D ● ● ● ●

Parts E ●

Parts F ● ●

Parts G ● ●
Process②
Parts H ● ●

System to position the Process① Parts I ● ●

processing point
Process② Parts J ● ● ● ●

Parts K ● ●
System to maintain the Process① ・ ・ ・ ・
continuity of the ・
・ ・
・ ・
・
・
・
processing point
Process② It can be to applied a variety of other 21
 Processing point analyze

Chapter 1.
Fin.

22
 Processing point analyze

Chapter 2.
Concept of processing point analysis

（Risk assessment, Condition setting）

23
 Risk Assessment

Example of Risk assessment in Rinsing machine

Risk of Quality trouble

Process Trouble in the past Trouble that can occur

Dent mouth of Misalignment gripper

Upside down bottle Contamination by fragment of
bottle packing

Scratch wall bottle

・
・ ・
・
・ ・

Inner rinsing － Less rinsing

・
・ ・
・
・ ・

Draining － Residual water

・
・ ・
・
・ ・

24
 P.22
Setting condition for manage each quality failure mode.

Process Failure mode Condition Parameter

Dent mouth bottle Centering gripper ±２mm
Upside down
Contamination Survey Survey
bottle
Collide with resin and No scratch by the
Scratch bottle bottle tentacles

Less rinsing Centering nozzle ±１mm

Inner rinsing Supply water volume 15t/hover （input）
Pressure rinsing water 1.5MPa±0.2

Draining Residual water Draining time More than 20sec

Gripping angle 15±2°

If there is a high standard of assurance level already, fill out current one. If not, investigate.

25
 Processing condition
Processing condition : Conditions for maintaining the
optimum conditions for processing point

Physical condition
Volume ： Flow rate, liquid weight, air content, electricity…
Power ： Pneumatic, hydraulic pressure, voltage, friction force ..
Displacement ： Angle, roughness, hardness, thickness, height, ...
Environmental change
Room temperature, Humidity…
UV, Radiation, Noise …

26
 Investigate/verification failure mode (Know-Why)

Process and Trouble Mechanism of failure that can Processing

that can occur occur from the processing point condition
Set by result of
verification
Upside down

Occurred contamination with chipped

Contamination by gasket by cｌash with mouth of bottle.
Clearance gripper
fragment of 5mm over with
gasket By gasket of cracks due to aging, bottle in position
occur contamination. start grip
Hardness of gasket

Material of gasket

27
 Processing point analysis

Chapter 2.
Fin.

28
 Processing point analysis

Chapter 3.
Concept of processing point analysis

(Deployment to process stabilization)

- Facility&Equipment inspection standard
- QM Matrix

29
QM Matrix

The purpose of QM matrix

１．Can use to pursuit of cause when occur trouble.

２．Can use for risk assessment when modify
equipment.

30
Structure of QM Matrix

4M

Parts
Failure mode

Spec/Std
Management item
Process
Condition Parameter

31
 Structure of QM Matrix

Parts name in System

diagram 4M

Parts
Trouble that can
occur in System
diagram
Failure mode

Spec/Std
Spec/Standard of
Management item parts in System
Process diagram
Condition Parameter

Process in System Processing condition

diagram in System diagram Indicate relation with
parts that form
processing condition.

Reflecting to maintenance / operation check sheet based on this QM matrix.

32
 Application of QM matrix

(Application to pursuit of cause when occur trouble. )

4M

Parts

Parts A

Parts B

Parts C

Parts D

Chemical A

Bottle Z
Failure mode

Spec/Std.

Material..

Setting ….
○ × □
○ × □ Management item
Process Paramete
Condition r
◎ ･･･Pressure ･･･MPa±

◎ Process１ ･･･Flow rate ･･･ｔ/s以下 ◎ ○

◎ ○ ･･･Temp ･･･℃以上

○ Process２ ･･･Speed ･･･bpm以下

33
 Application of QM matrix

(Use for risk assessment when modify equipment. )

4M

Parts

Parts A

Parts B

Parts C

Parts D

Chemical D

Bottle Z
Failure mode

Spec/Std.

Material..

Setting …
○ × □
○ × □ Management item
Process Paramete
Condition r
◎ ･･･Pressure ･･･MPa±

◎ Process1 ･･･Flow rate ･･･ｔ/s以下 ◎ ○

◎ ○ ･･･Temp ･･･℃以上

○ Process2 ･･･Speed ･･･bpm以下

34
 Processing Point Analysis

Chapter 3.
Fin.

35