TPM Club India
Autonomous Maintenance Pillar
PILLAR
Jishu Hozen
or
Autonomous Maintenance
TPM Club India
Autonomous Maintenance Pillar
Reasons Why Autonomous Maintenance is Required
No satisfactory increase in the
performance record can be seen …
• Confirmation of
working conditions
• Daily inspection
• Periodical inspection
Activities to keep
record on equipment
degradation
Activities to prevent
equipment
degradation
• Keep cleaning
• Inspection
• Additional
tightening
Preventive
Maintenance
Production
Maintenance
U.S style of PM
Maintenance
Department’s
sole
responsibility
Activities to
restore the
machine
conditions
TPM
Japanese
style of PM
• Frequent servicing
• Solution of abnormality
• Good communication
TPM Club India
Autonomous Maintenance Pillar
Autonomous Maintenance
•Inspect & lubricate daily
•Replace parts and make repairs
•Detect abnormalities early
•Check precision
I take care of
my own machine
TPM Club India
Autonomous Maintenance Pillar
Classification of Maintenance and Responsibility
Implementation
Classification
Prevention
Measurement
Restoration
Proper Operation
Normal Operation
Set-up and adjustment
Cleaning, Address Latent Defects
Preventive
Maintenance
Lubrication
Daily Maintenance
Retightening
Operation Condition, Daily Inspection for
Deterioration
Minor Check
Time – based Inspection
Time based
Maintenance
Productive
Maintenance
Time – based Inspection
Time – based Check
Tend Check
Predictive
Maintenance
Unscheduled Check
Strength KAIZEN
Corrective Maintenance
(Reliability)
Corrective
Maintenance
Lightening of Loading
Accuracy Improvement
Corrective
Maintenance
(Maintain-ability)
Conditions Monitoring
KAIZEN of Check Operation
KAIZEN Of Check Operation
Others
Maintenance
Prevention
Breakdown
Maintenance
Check Quality KAIZEN
MP Activities
Planned Breakdown Maintenance
Emergency Maintenance
Earlier discovery of interior situation and positive
and rapid report/remedy
Sporadic Repair
Assigned
Operati
Maintena
on
nce
TPM Club India
Autonomous Maintenance Pillar
Relationship Between Forced Deterioration and Losses
Example of Forced Deterioration
Due to Inadequate Cleaning
1. Cause of failure Contamination by dirt or fallen matter in rotating
parts, sliding parts, air and oil pressure systems,
electrical control systems, sensors, etc. causes a
drop in accuracy, misoperation or a failure due to
wear, jamming, resistance, poor electrical
conductivity, etc.
2. Cause of quality Direct contamination by foreign matter in products
and misoperation of equipment results in quality
defects.
3. Cause of forced Waste and dirt makes it difficult to inspect for
deterioration
looseness, cracks, play and out-of-oil conditions,
resulting in forced deterioration.
4. Cause of speed Dirt increases frictional resistance and sliding
losses
resistance resulting in speed losses such as
decreased performance and idling.
TPM Club India
Autonomous Maintenance Pillar
Examples of Steps for Evolving Autonomous
Maintenance
Step
Name
1
Initial clean-up
All-around clean-up of dust and dirt, centering on equipment proper,
and implementation of lubrication, and machine parts adjustment;
discovery and repair of malfunctions in equipment
2
Measures against Sources
Prevent causes of dust and dirt and scattering, improve places which are
difficult to clean and lubricate and reduce the time required for clean-up
and lubrication.
3
Formulation of clean-up and lubrication Formulate behavioral standards so that it is possible to steadily sustain
standards
clean-up, lubrication and machine parts adjustment in a short period
(Necessary to indicate a time frame-work that can be used daily or
periodically)….
4
Overall inspection
Training in check-up skills through check-up manuals; exposure and
restoration of minor equipment defects through overall check-ups
5
Autonomous check-up
Formulation and implementation of autonomous check-up sheets
6
Orderliness and tidiness
Standardize various types of on-the job management items and devise
complete systematization of up-keep management.
• Standards for clean-up, check-ups and lubrication
• Standards for physical distribution in the workplace
• Standardization of data records
• Standardization of die management, jigs and tools
7
All-out autonomous management
Development of corporate policies and goals, and making improvement
activities routine : Steadily record MTBF analysis, analyze these, and
carry out equipment improvements
TPM Club India
Autonomous Maintenance Pillar
Four Steps to Become An Operator Strong on
Equipment And Autonomous Maintenance
Autonomous
Maintenance
7 steps
7 All-out autonomous management
6 Orderliness and tidiness
5 Autonomous check-up
4 General inspection
3 Formulation of clean-up and lubrication
standards
2 Measures against sources of outbreaks
1 Initial clean-up
Four steps to
become an
operator strong on
equipment
4 Master how to repair the equipment
Learn how to operate the equipment
3 with the required accuracy and how to
evaluate the product quality
2 Study the mechanism and functions of
equipment and machines
Familiarize with the concept of equipment
1 maintenance and improvement and with how
to put the idea into practical realization
TPM Club India
Autonomous Maintenance Pillar
How to Concretely Develop “Jishu-Hozen”
The outline is mentioned in the 1st through 3rd stages, but how to
concretely develop the activities is as per Table IV-2.
Table IV -2
Development of “Jishu-Hozen” (For equipment)
2nd
Activities
Target
Guidance and
promotion
Equipment
Operator
• Prevention of forced
deterioration caused by
dust or dirt
• Discovery and
rectification of latent
defects thorugh clean-up
• Discovery of areas where
clean-up and inspection
are difficult
• Removal of unnecessary
things around equipment
• Rationalization of
lubrication
• Formation of mind
attachment to the
equipment through
touching and handling
the equipment
• Cultivation of the
ability to identify
equipment “fuguai”
• Recognition of the
importance of cleanup
• Pointing out and
guidance of the priority
clean-up areas.
• Instruction in the
importance of clean-up
(education)
• Preparation of
diagnosis sheets
• Responsibilities in the
operation and
implementation of
activities
Counter• Implementation of countermeasures • Making the equipment
• KAIZEN of nearby
measures for
against such sources as dust and dirt,
cleaning and inspection
items to practice and
the causes
and prevention of splashing of leaks
easy through improvement
to master the
of forced
of
the
sources
of
dust
and
application of the
• Implementation of countermeasures
deterioration
dirt, and areas where
KAIZEN method and
against the areas where cleaning and
and
inspection and cleaning
concept
inspection are difficult (Operation
improviding
are difficult
improvement for shortening the time
• Enjoy the KAIZEN
hard-to
needed for cleaning and service)
• Improvement of
activities (Pleasure of
access areas • Ranking the priority places for daily
maintainability
hand-made)
inspection
• Confirmed of KAIZEN and its effect
• Concept and practice of
equipment KAIZEN
• How to prepare the
criteria or standards
• Implementation of
visual control and
instruction on device
development
• Complete elimination of dust and
dirt, especially on equipment
• Performance of lubrication and
retightening, and discovery and
rectification of slight equipment
Initial cleandefects
up
(Cleaning • Removal of unnecessary things,
orderliness and tidiness of tools and
and
jigs
inspection
© JIPM, 1987
* Trained operators to be proficient in equipment and reduction in failure rate
1st
Category
* Establish of basic conditions (cleaning, lubrication and retightening)
Step
TPM Club India
Autonomous Maintenance Pillar
How to Concretely Develop “Jishu-Hozen” (Contd.)
Category
Activities
Target
Equipment
3rd
Preparation
of tentative
“JishuHozen”
standards
• Preparation of action criteria to
• Keeping the 3 basic
allow positive clean-up, lubrication
elements of equipment
and retightening maintenance within
maintenance clean-up,
shortest time
lubrication and
relighting
• KAIZEN of inspection method and
visual control
• Mastering inspection skill, utilizing •
inspection manuals
• Discovery and restoration of general
inspection
• Preparation of autonomous
inspection standards
4th
General
inspection
•
•
Autonomou
s inspection
5th
Operator
Guidance and
promotion
• Review clean-up, lubrication and
•
general inspection criteria and
integrate them into comprehensive
criteria to contribute to efficiency
activities
•
• Preparation and implementation of
autonomous inspection check sheets
• Improvement of visual control and
operability
• Self-decision of criteria • Preparation of
and its strict observance
standards for
technologies and
• Each worker learns to be
techniques
aware of individual
roles.
• Clarification of
procedures to study
what the equipment
must be
Restoration of
• Acquaintance of
• Preparation of
deterioration by
inspection skill
training text for
exterior general
general inspection
• Understanding the
inspection of
equipment functions and • Planning of education
equipment and
mechanism
and training schedule
reliability
• Mastering how to put
• Execution of leader
improvement.
together data and how to
training
KAIZEN of areas
use it
• Follow-up of
where remedial action • Activation through
education and
and normal inspection
KAIZEN activities
training
are difficult
• Learning the importance • Preparation of
Making inspection
of education on
general inspection
efficient
communication
manual and check
sheets
Positively keeping the • Maintenance of one’s
• Teaching how to
restoration from
own equipment by
precisely analyze the
deterioration by means
oneself
data
of general inspection
• Self-decision and strict
• Effective equipment
KAIZEN of equipment
observance
management and
which has good
maintenance
• “Jishu-Hozen” is
operability
learning what the ideal
* Through implementation and maintenance of inspection
Step
© JIPM, 1987
TPM Club India
Autonomous Maintenance Pillar
How to Concretely Develop “Jishu-Hozen” (Contd.)
Activities
Target
Equipment
• Picking the items to be
managed
6th
Standardization
• Standardization of
management items and
systematization of
maintenance management
• Development of company
policy/goals and quantitative
analysis of KAIZEN
activities
Autonomous
management
7th
• Positive implementation of
MTBF analysis and
recording
(Recording failure by visual
control) and equipment
KAIZEN
Operator
Guidance and
promotion
• KAIZEN of
equipment reliability,
maintainability and
operability
• Improvement of
• Technical guidance to
management technology
promote
standardization
• Expansion of “JishuHozen” management
• Revision of
• Review and KAIZEN
scope
management
of equipment
standards and
• Thoroughness of visual
environment and
thoroughness of
control
layout
management
• Kaizen of equipment
reliability
maintainability and
operability through
equipment KAIZEN
by applying various
data analysis
• Keeping overall
equipment efficiency
at its best
• Enhancement of goal
• Technical assistance
consciousness and
for equipment
thorough cost
KAIZEN
consciousness, including
• Standardization of
maintenance cost
improved items
• Acquirement of skill to
• Education and
perform minor repair by
training in repair
oneself
skills
• Acquisition of data
recording and analyzing
technique and KAIZEN
technology
© JIPM, 1987
* Making the strong structure which can perform “Jishu-Hozen management
Category
* KAIZEN activities, including those for problems related to equipment
Step
TPM Club India
Autonomous Maintenance Pillar
Step 1 - Initial Cleaning
KEY POINTS
•
•
•
•
Cleaning with Meaning
Cleaning for no cleaning
Inspection means finding problems
Identification of abnormalities
TPM Club India
Autonomous Maintenance Pillar
Any thing
wrong here
We’ll clean
every nook
and corner
Anything we
can fix right
away, we will
Cleaning is inspection
TPM Club India
Autonomous Maintenance Pillar
Step 1 - Initial Cleaning : Activities
 Thorough cleaning of machines and identify
White tag Red tag
fuguai.
 Attaching tags for fuguais depending upon the
nature.
 White tags for fuguais to be attended by the
operatives.
 Red tags for fuguais to be attended by the
specialists ( Maintenance personnel or subcontractor)
 Green tags for fuguais found in the similar type
Green tag
of machines also to be considered for JH
machines.
 Fuguais will be linked to conditions which may
lead to breakdown, defect and unsafe
conditions.
 Do audit and get passed.
 Go for step 2.
TPM Club India
Autonomous Maintenance Pillar
Table 4-6. Sample Manual on Exposing Seven Types of Abnormality
Abnormality
1. Minor flaws
• Contamination
• Damage
• Play
• Slackness
• Abnormal phenomena
• Adhesion
2. Unfulfilled Basic Conditions
• Lubrication
• Lubricant supply
• Oil level gauges
• Tightening
3. Inaccessible Places
• Cleaning
• Checking
• Lubricating
• Tightening
• Operation
• Adjustment
4.
Contamination Sources
• Product
• Raw Materials
• Lubricants
• Gases
• Liquids
• Scrap
• Other
Examples
Dust, dirt, powder, oil, grease, rust, paint
Cracking, crushing, deformation, chipping, bending
Shaking, falling out, titling, eccentricity , wear, distortion, corrosion
Belts, chains
Unusual noise, overheating, vibration, strange smells, discoloration, incorrect pressure or current
Blocking, hardening, accumulation of debris, peeling, malfunction
Insufficient, dirty, unidentified, unsuitable or leaking lubricant
Dirty, damaged, or deformed lubricant inlets, faulty lubricant pipes
Dirty, damaged, leaking ; no indication of correct level
Nuts and bolts : slackness, missing, cross-threaded, too long, crushed, corroded washer unsuitable,
wing nuts on backward
Machine construction, covers, layout, footholds, space
Covers, construction, layout, instrument position and orientation, operating – range display
Position of lubricant inlet, construction, height, footholds, lubricant outlet, space
Covers, construction, layout, size, footholds, space
Machine layout : position of valves, switches, and levers : footholds
Position of pressure gauges, thermometers, flow meters, moisture gauges, vacuum gauges, etc.
Leaks, spills, spurts, scatter, overflow
Leaks, spills, spurts, scatter, overflow
Leaking, split, and seeping lubricating oils, hydraulic fluids, fuel oil,etc.
Leaking compressed air, gases, steam, vapors, exhaust fumes etc.
Leaking split and spurting cold water, hot water, half-finished products, cooling water, waste water
etc.
Flashes, cuttings, packaging materials, and nonconforming product
Contaminants brought in by people, fork-lift trucks, etc. and infiltrating through cracks in buildings
TPM Club India
Autonomous Maintenance Pillar
Table 4-6. Sample Manual on Exposing Seven Types of Abnormality : Contd...
Abnormality
5.
Quality Defect Sources
• Foreign matter
• Shock
• Moisture
• Gain size
• Concentration
• Viscosity
6.
7.
Unnecessary and Nonurgent items
• Machinery
• Piping equipment
• Measuring instruments
• Electrical equipment
• Jigs and tools
• Spare parts
• Makeshift repairs
Unsafe Places
• Floors
• Steps
• Lights
• Rotating machinery
• Lifting gear
• Other
Examples
Inclusion, infiltration and entrainment of rust, chips, wire scraps, insects etc.
Dropping, jolting, collision, vibration
Too much, too little, infiltration, defective elimination
Abnormalities in screens, centrifugal separators, compressed – air separators etc.
Inadequate warming, heating, compounding, mixing, evaporation, stirring, etc.
Inadequate warming, heating, compounding, mixing, evaporation, stirring etc.
Pumps, fans, compressors, columns, tanks, etc.
Pipes, hoses, ducts, valves, dampers, etc.
Temperatures, pressure gauges, vacuum gauges, ammeters, etc.
Wiring, piping, power leads, switches, plugs etc.
General tools, cutting tools, jigs, molds, dies, frames, etc.
Standby equipment, spares, permanent stocks, auxiliary materials, etc.
Tape, string, wire, metal plates, etc.
Unevenness, ramps, projections, cracking, peeling, wear (steel deckplates)
Too steep, irregular, peeling anti-slip covering, corrosion, missing handrails
Dim, out of position, dirty or broken covers, not properly explosion-proofed
Displaced, fallen off or broken covers, no safety or emergency stop devices
Wires, hooks, brakes, and other parts of cranes and hoists
Special substances, solvents, toxic gases, insulating materials, danger signs, protective
clothing etc.
TPM Club India
Autonomous Maintenance Pillar
Identification of forced deterioration
TPM Club India
Autonomous Maintenance Pillar
TPM Club India
Autonomous Maintenance Pillar
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Autonomous Maintenance Pillar
TPM Club India
Autonomous Maintenance Pillar
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Autonomous Maintenance Pillar
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Autonomous Maintenance Pillar
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Autonomous Maintenance Pillar
EXAMPLE OF ABNORMALITY
( LOOSE FITTINGS )
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Autonomous Maintenance Pillar
EXAMPLE OF ABNORMALITY
( LEAKAGES )
TPM Club India
Autonomous Maintenance Pillar
ABNORMALITY TAGS
White Tags Removed by Line Operators
Red Tags Removed by Skilled Person
TPM Club India
Worn-out
Autonomous Maintenance Pillar
TPM Club India
Autonomous Maintenance Pillar
ELIMINATION OF FORCED
DETERIORATION
Before
After
TPM Club India
Autonomous Maintenance Pillar
ELIMINATION OF FORCED
DETERIORATION
Before
After
TPM Club India
Autonomous Maintenance Pillar
Step 2 - Measures against
Sources
KEY POINTS
• Stop contamination at source
• Minimise (localise) contamination
• Easy to Clean, Lubricate, Retighten &
Lubricate
• Uncover to discover
• Take counter measure against Forced
deterioration
TPM Club India
Autonomous Maintenance Pillar
EASY TO CLEAN
Means easy to clean,
collect, dispose & inspect
Use of localised guards
TPM Club India
Autonomous Maintenance Pillar
Step 2 : Countermeasure for the causes of Forced Deterioration and Improving and Hard-to Access Areas
Purposes :
• Eliminate sources generating dirt, dust and stains, prevent splashing and flying and improve places
that are hard to access, oil and check to shorten the time needed for cleaning, oiling and inspection
• Learn approach to equipment KAIZEN and achieve tangible results
© Understand evils of dirt,
stains, dust and foreign matter
Gather quan-tified data
© Why do they generate ?
© Learn how to think of
KAIZEN
© Find places with dirt, stains, dust and foreign
matter accumulated
© Analyze dirt, stains, dust and foreign matter
 material, shape and
composition
© Analysis of generating sources
• Do they generate in a prior processes ?
• Do they generate in one’s own process ?
• Are they generated by machining ?
• Are they generated by equipment ?
• Do they come form the outside the plant ?
©
•
•
•
•
© What are hard-to-access areas
• Time-consuming places
• Places difficult to do
© What type of work is performed?
• Cleaning, oiling, inspection
• Which tools are used ?
• Can work be performed in a visible
state ?
• How are results checked?
• Visual examination hand….
© Devise countermeasures
• Goal time
• Improvement method
Devise countermeasures
Eliminate generating sources
Prevent splashing and flying
Prevent instrusion and attaching
Schedule, operators in charge, plan
Present daily cleaning
and inspection goal
time
• Eliminate
• Focus
Restoration and KAIZEN
•Prevent
splashing and
flying
Check results of KAIZEN measures
Reexamine tentative cleaning standard
Matters pointed
out
Clean in accordance with tentative cleaning standard
Autonomous audit
KAIZEN records
Reexamine tentative standard prepared in
step 1 and tentative standard improved
afterward
Check if cleaning can be finished accurately
within time specified in tentative standard and
remove
“EFU”
Circle activity report, application for
plant audit
Plant audit
© JIPM, 1987
Passed
•………
•………
•………
Activities board
TPM Club India
Autonomous Maintenance Pillar
TPM Club India
Autonomous Maintenance Pillar
Minimise Contamination
TPM Club India
Autonomous Maintenance Pillar
Modify equipment to make cleaning easier
TPM Club India
Autonomous Maintenance Pillar
Install covers and inspection windows to
make checking easier
TPM Club India
Autonomous Maintenance Pillar
SOURCE OF CONTAMINATIONS
TPM Club India
Autonomous Maintenance Pillar
IDEA FOR ELIMINATING
FORCED DETERIORATION
TPM Club India
THEME:
Autonomous Maintenance Pillar
KAIZEN
LOSS NO
MACHINE:
LOSS STRUCTURE:
To reduce Cleaning time
BENCH MARK
30 Sec
TARGET
5 Sec
8A
Cleaning Time Reduction
COUNTERMEASURE:
Before
Oi
lC
Cleaning the contaminated
material deposited in the magnet
takes more time
hu
Contaminated
material
te
KAIZEN START
TEAM:
IDEA:
To provide a polythene paper on the
magnet to collect contaminated material
PROBLEM:
13B5SL
S.Ravindharan
V.Mohan
P.Comarasen
K.Patchaiappan
15.03.2001
KAIZEN FINISH
16.03.2001
BENEFITS :
After
Oi
lC
hu
Contaminated
material
te
Polythene
Magnet
Paper
Magnet
• Time saving / month
= 533 min
• Timings saving / Year
= 6396 min
• Effortless activity
Oil tank
Remove magnet &
cleaning by brush with
diesel then fix magnet
ANALYSIS:
WHY 1
Cleaning
the
magnet
takes
more
time
Oil tank
No cleaning remove
Polythene paper and fix
new polythene paper
HORIZONTAL DEPLOYMENT :
RESULT:
WHY 2
WHY 3
Iron
particles
not
coming
out
easily
from
magnet
Due to
magnetic
property
Sec
30
Before
After
30 Sec
BETTER
15
5 Sec
0
Area
Status
Socket
13
Hex
15
Special
13
TPM Club India
THEME:
Autonomous Maintenance Pillar
KAIZEN
LOSS NO.
To Reduce Cleaning Time inside the
machine area in rolling machine
BENCH MARK
8A
LOSS STRUCTURE:
Cleaning Time Reduction
CGR17H
TEAM: J. Srinivasan
KAIZEN START
03-06-2001
S.Jayaraman
3 min / shift
IDEA:
To provide gaurds in the product discharge chute &
providing conveyor
“Zero”
TARGET
MACHINE:
PROBLEM:
COUNTERMEASURE:
Before
Krishnamoorthy
D.Sivakumar
KAIZEN FINISH
21-06-2001
G. Devanathan
BENEFITS :
After
Gaurd
Time saving = 3 Min / Shift
Man hours saved per year = 15 hours
Time taken for cleaning inside the
machine area is more
Other Benefits
No Spill Over of Products
Tray
Product
spillover
ANALYSIS:
WHY 1
Cleaning time
Problem : Cleaning time is more
WHY 2
WHY 3
Products get
Basic design
is more in
spilled over
inside the
inside the
machine area
machine area
in rolling
and oil leakage
machine
from chute
No oil leakage
Oil
S-Conveyor
Oil Pit
RESULT:
HORIZONTAL DEPLOYMENT :
mts
3 min / shift
3
Better
of chute
No of rolling machines
Identified
: 9 Nos.
Implemented : 6 Nos.
Zero
0
Before
After
Target Date
25-09-2001
TPM Club India
Autonomous Maintenance Pillar
EXAMPLES OF LOCALISED CONTAINMENT
Before
After
TPM Club India
Autonomous Maintenance Pillar
Usage of
localised guards
TPM Club India
Autonomous Maintenance Pillar
Eliminate cleaning by fabricating chute for collecting
disposable waste.
After
Before
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Autonomous Maintenance Pillar
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Autonomous Maintenance Pillar
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Autonomous Maintenance Pillar
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Autonomous Maintenance Pillar
Actions to eliminate dust falling on the floor
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Autonomous Maintenance Pillar
Easy to lubricate
TPM Club India
Autonomous Maintenance Pillar
Countermeasures against source of contamination
Oil Localisation
Before
After
Localised gaurds
The return oil flow from the feed drive gears splash and spread all around the
open space inside the machine there by getting contaminated. To avoid the
contamination, the return oil flow is channalised from the feed drive gears
directly to the lubrication tank
TPM Club India
Autonomous Maintenance Pillar
Easy to Lubricate
Before
Machine cover
After
Machine cover
Grease points
Pulley
In TM19B tapping machine the plummer block
bearings (2 nos in every spindle and there are 4
spindles) are lubricated once a week. This activity
takes 20 minutes since the lub points are inside and
machine covers to be removed and again
assembled. It is also difficult to do this activity as the
grease points are in “Hard to access” areas.
Pulley
Grease points
The grease points have been brought
out by means of tubes and greasing is
done even when the machine is
running. In addition to avoidence of
loss of time,. It is also safe to carry out
this activity like this.
TPM Club India
Autonomous Maintenance Pillar
DIFFICULT TO LUBRICATE
- EASY TO LUBRICATE
Before
Difficult to Lubricate the oil to
gear box
After
Easy to Lubricate the oil to
gear box
TPM Club India
Autonomous Maintenance Pillar
Easy to Retighten
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Autonomous Maintenance Pillar
TPM Club India
Autonomous Maintenance Pillar
Easy to Inspect
TPM Club India
THEME:
Autonomous Maintenance Pillar
KAIZEN
LOSS NO.
LOSS STRUCTURE:
To reduce Inspection time
BENCH MARK
TARGET
MACHINE:
8A
2 sec / Day
PROBLEM:
Inspection Time Reduction
COUNTERMEASURE:
Before
KAIZEN START
TEAM: J. Sriram
10.05.2001
Karunairaja
IDEA:
To bring the pressure gauge for K.O. system outside the
machine for easy inspection
30 sec / Day
10B3S
After
Franklin
KAIZEN FINISH
25.05.2001
Sivakumar
Ramalingam
BENEFITS :
Time saving = 28 sec / Day
Man hours saved per year = 15 hours
Inspection is very difficult and
taking more time in the pressure
gauge for K.O. system
Pressure
gauge
Inside the M/c
Difficult to
Inspect
ANALYSIS:
WHY 1
Inspection is
very difficult
and it is
taking
Problem : Inspection is difficult
WHY 2
WHY 3
Pressure gauge
By machine
kept inside the
design
Pressure
gauge
Outside the M/c
Other Benefits
Inspection becomes easy
Easy to
Inspect
RESULT:
HORIZONTAL DEPLOYMENT :
Sec.
30 sec / change
30
Better
No of Areas
machine
Identified
15
: 5 Nos.
moretime in
pressure
gauge for
K.O. system
2 sec / Day
0
Before
After
Implemented : 5 Nos.
TPM Club India
THEME:
Autonomous Maintenance Pillar
KAIZEN
LOSS NO
MACHINE:
LOSS STRUCTURE:
To reduce Inspection
time
8A
BENCH MARK
10 Sec / Inspection
TARGET
1 Sec / Inspection
PROBLEM:
IDEA:
To provide oil level visual indicator
outside the gear box
COUNTERMEASURE:
Before
19.03.2001
Jayaraman
Devanathan
Krishnamoorthy
Sivakumar
KAIZEN FINISH
31.03.2001
BENEFITS :
After
Dip
Stick
Max
To check the oil level in gear box
is very difficult & take more time
KAIZEN START
TEAM:
Inspection Time Reduction
Lock
screw
17B3S
Gear
Box
Gear
Box
• Time saving / month
= 270 Sec
• Timings saving / Year
= 3240 Sec
• Effortless activity
Min
* Unlock Screws
* Remove Dip stick
* Inspect
* Assy dip stick
* Lock screw
ANALYSIS:
WHY 1
Inspection
the oil
level takes
more time
* Inspect Only
HORIZONTAL DEPLOYMENT :
RESULT:
WHY 2
WHY 3
Method of
inspection
is difficult
Basic
machine
design
Sec
10
Before
After
Area
10 Sec
Socket
BETTER
5
Special
1 Sec
0
Hex
Status
`
`
`
8/13
11/15
7/13
TPM Club India
Autonomous Maintenance Pillar
Easy to Clean & Inspect
Before
Motor Inside
The 10b3s forging machine was fully
covered which makes difficult to clean &
inspect in the motor, fly wheel area
After
Motor Outside
The C’measure was taken by opening
the side cover of the machine & an See
thru sheet was provided which makes
easy to clean and inspect, the motor and
flywheel.
TPM Club India
Autonomous Maintenance Pillar
TPM Club India
Autonomous Maintenance Pillar
TPM Club India
Autonomous Maintenance Pillar
DIFFICULT TO INSPECT- EASY TO INSPECT
Before
Difficult to Inspect the belt
condition
After
Easy to Inspect the belt condition
TPM Club India
Autonomous Maintenance Pillar
Rearranging cables / hoses for easy inspection
Before
After
TPM Club India
Autonomous Maintenance Pillar
Step 3: Formulation of cleanup and lubrication standards
• Learn the structure and functions of
your own equipment (training by
leader)
• Test your understanding and then
actually inspect the equipment
• Correct new problems found
• Establish through visual controls to
help control equipment conditions
TPM Club India
Autonomous Maintenance Pillar
TPM Club India
Autonomous Maintenance Pillar
Step 3 : Preparation of Tentative “Jishu-Hozen” Standards
Purposes :
• Basic conditions of activities to prevent equipment deterioration -- Maintenance and management of
cleaning, lubrication and retightening
• Action standard allowing accurate maintenance of basic conditions quickly is prepared by oneself
• New ideas for visual control
(Steps 1 and 2)
List of slight defects
found
Kaizen records
Check goal time
©
•
•
•
•
•
Cleaning and inspection
Clarify places
Clarify method
Clarify standard
Clarify troubleshooting
Clarify period
©
•
Set goal time
•
•
•
•
•
Lubricating
Lubrication places, lubrication types,
lubrication levels, tools
Clarify period
Identify lubrication work trouble and
problems
KAIZEN
Set goal time
Prepare standard
© Utilize visual control
Cleaning, lubrication and inspection
Guidance items
Maintenance
department
Lubrication manual
Lubrication training
© Study what is wrong with existing
standards
© Study why they could not be followed
Difference with goal time
KAIZEN
KAIZEN records
Implement and confirm
Activity records
Autonomous audit
Circle activity report and
plant audit application
Plat audit
Passed
•………
•………
•………
•………
•………
Activities board
Passed * * *
© JIPM, 1987
TPM Club India
Autonomous Maintenance Pillar
Cleaning and
Lubricating
Inspection
1) Lubrication
1) Clarify Places
Places,Types,Levels,tools
2) Clarify method
2) Clarify Period
3) Clarify Standard
3) Identify lubrication work
trouble & problems, Make
4) Clarify
Troubleshooting
5) Clarify Period
Lubrication Manual
4) Kaizen
Set Goal time
TPM Club India
Autonomous Maintenance Pillar
MAJOR GUIDELINES TO PREPARE JH STANDARDS
•
Study the existing M/C check sheet & Analyse the reasons,
why is it not maintained and used effectively.
•
All the cause and problems should be addressed & rectified
while preparing new standards
•
Set Goal time for all activities put together-Cleaning,
Lubrication, Inspection & Retightening, set it separately for
D,W,M & Y activities
•
Consider Stratification of Fuguais & see to that no Fuguai is
missed, which needs to be addressed in standards to prevent
Forced deterioration
TPM Club India
•
Autonomous Maintenance Pillar
Clarify place, method, standard, troubleshooting, period, tool,
frequency etc. So that no ambiguity and subjectivity remains
in mind while taking decision for any point in the standard
•
The standards should be rational and should consider all
points necessary to maintain its basic operating conditions
and prevent equipment deterioration.
•
Bring in More VISUAL CONTROLS so during inspection
decision can be made easily & correctly by the person about
check points.
•
Revise the standards after implementing any Kaizen
TPM Club India
Autonomous Maintenance Pillar
VISUAL CONTROLS
Activity
CLEAN
LUB
INSPECTION
Symbol
Tools
I
S
NOC
TPM Club India
Autonomous Maintenance Pillar
COLOUR CODE FOR FREQUENCY
TPM Club India
Autonomous Maintenance Pillar
DAILY INSPECTION ROUTE
BEFORE STEP-3
9
1
8
7
6
2
5
3
4
Machine - Shigiya 138 - Grinding Machine
TPM Club India
Autonomous Maintenance Pillar
TPM Club India
Autonomous Maintenance Pillar
TPM Club India
Autonomous Maintenance Pillar
JISHU-HOZEN CHECK SHEET
POINT NO. 3 HYDRAULIC TANK FRONT,LUB TANK,FRL AND WORK HEAD BACK
MACHINE : C P BORING
CELL : CONNECTING ROD
SL. NO
CHECK ITEM
D
1
HYDRAULIC TANK FRONT
1a
Outer body
1b
Pipe Joints
W
M
STND.
VALUE 1
2
3
4
5
6
7
8
9
PLANT : ENGINE PLANT
10
11
MONTH : JANUARY
12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
No dirt &
dust
No Leak
btwn.
Max &
Min.
1c
Oil level indicator
1d
Oil pressure Gauge
2
LUBRICATION TANK
2a
Tank outer body
2b
Level indicator
2c
El. Jn. Wiring
2d
Lub Pipe joints
in Green
Zone
No dirt &
dust
btwn.
Max &
Min.
3M
No Leak
Checked By :
Sign. Of Supervisor
REVISION NO.
LEGENDS - (
) - OK ,
(
1
) - NOT OK ,
2
(
) - NOT OK,RECTIFIED BY SELF ,
4
3
(
) - NOT OK, INFORMED SUPERVISORP,
(
) - PLANNED.
TPM Club India
Autonomous Maintenance Pillar
TENTATIVE CLEAN LUB INSPECT
STANDARDS
Jishu - Hozen ( Tentative Cleaning, Lubrication and Inspection ) Standards
Cell : Nozzle Cell
Equipment description : Micromatic OD Grinding Machine
Illustration
Tail stock
Classification
Inspection
No.
1
Equipment number : M12045
Place or section
Tailstock
Standards
With in the indicated
Cirlce name : NOZH 1
Method
Visual
value range
Cleaning
2
Tailstock
Free from mist & dust
Waste cloth
Inspection
3
Table Lubrication
With in the indicated
Visual
value range
Inspection
4
Loader Pistion
No Damage
Tools and Time Cycle
handling
N
I
N
Remove the
3mm
Pistion block
Allenkey
sec (month)
Person
in
charge
2
W
OP
30
W
OP
2
W
OP
1200 1 M
OP
During
During
operation stoppage
b
b
b
b
Keys : D : Daily; W : Weekly; SC : Setting change; PM : Maintenance staff; OP : Operator.
TPM Club India
Autonomous Maintenance Pillar
Aiders : Visual controls
TPM Club India
Indication marks
for nuts & bolts
Autonomous Maintenance Pillar
Indication for
valve controls
TPM Club India
Operational range
on indicators
Autonomous Maintenance Pillar
Direction flow indicators
TPM Club India
Fan to indicate the
function of Chiller Unit
Autonomous Maintenance Pillar
Arrow sign for
indicating the
rotating direction of
Motor
TPM Club India
Color code for Lubrication oil
Autonomous Maintenance Pillar
Display of sub equipment name
TPM Club India
Autonomous Maintenance Pillar
TPM Club India
Autonomous Maintenance Pillar
ONE POSITION INSPECTION
Hydraulic
tank
Lube oil
tank
Before – Hydraulic tank and
Lubrication tank in different
position.
After – Hydraulic tank and
Lubrication tank in one position.
TPM Club India
Autonomous Maintenance Pillar
Initial Clean-up
( Cleaning is Inspection)
( Cleaning with meaning)
(Doing with purpose)
Taking countermeasure
for forced deterioration
and improving hard
to access area
Preparing tentative
standards for cleaning
and lubrication
TPM Club India
Autonomous Maintenance Pillar
Example of Activities Board
Leader
Sub leader
Circle
Members
Section and Subsection
Goals and Measures
Policies
Kobetsu-Kaizen
Themes !
Reason for Selection
Understand Present status
Analysis
Troubleshooting and Schedule
Accomplishment Indices
Overall Efficiency
Availability
Non Defe-ctive
Rate
Performance Rate
Rework
Defect
Minor
Stoppag
e
Speed
Failure
Acceptance
Effect
Prevention of Recurrence,
Remaining problems
Jishu-Hozen
Activity Schedule
Number of Suggestions
*
Fuguai List
Efu Attaching
Removing
and
One-Point Lesson
List of Doubts
Actual Work
Meetings
Activities
“Good to Find” Corner
Photo
Before
Before
Source : Our TPM
© JIPM, 1994
TPM Club India
Autonomous Maintenance Pillar
Concept of “Jishu-Hozen”
Change in concept
Step 0
Motivation
Step 1
Step 2
Step 3
Change
equipment
Step 4
Step 5
Effect
Reduced
defects and
failures
• Think and act
• Rectify “Fuguai”
• Process of
actions is
head-spring of
motives
• Cleaning is
inspection
• Inspection is a step
to find “Fuguai”
• “Fuguai” should and
could be restored or
improved
• Why does
forced
deterioration
occur ?
• Needs of
“Jishu-Hozen
Enhance ability to find
and improve “Fuguai”
Defects and
failures are the
shame of the
Production shop
Step 6
Step 7
Effect
Operator’s
Change
Zero defects
and failures are
realized
Production
shop
changes
Change in activities
• Positive
challenge for
KAIZEN.
• Thoroughness of
maintenance and
management
• Restoration and KAIZEN are a
kind of success.
• Success is a pleasure as a result
of achievement
(Unless
success
can
be
expected, the operators will not
change their mind.)
• Bottom up from circle
activities
• Autonomous KAIZEN
by operators
TPM Club India
Autonomous Maintenance Pillar
Keypoints for Autonomous Maintenance Success and Check
Points of Controller Roles
1. Introductory education…………….……..
Is TPM well understood ?
2. Cooperation between Divisions……….
Are the assistance and cooperation of other divisions
towards the production division satisfactory ?
3. Main Body of Circle Activities…………..
Are the overlapping small group activities adopted ?
4. The work itself …………………………..
Has the concept of “Autonomous Maintenance is the work
itself “ been established
5. Practice – First ………………………..….
Instead of insisting on forms and theroy, are people
learning by experience ?
6. Education & Training…………………….
Are training education and training done in accordance
with the step
7. Substantial effect…………………………
Are substantial effects obtained in accordance with the
steps ?
8. The matters to be observed shall………. be decided by
oneself
Is there the capacity to decide by oneself ?
9. Autonomous Maintenance……………… Diagnosis
Are the diagnosis and guidance of the controller
adequate?
10. Model Selection…………………………..
Is the selection of the model adequate ? Is the guidance of
the controller good ?
11. Rapid Processing of ………………..…… Plant
Is the processing of non-conformity points and
improvements done rapidly ?
12. Make it Thorough…………………………
Aren’t the steps merely followed by formality?
TPM Club India
Autonomous Maintenance Pillar
Step 4 : General Inspection
Purposes :
• Understand structures, functions, principles and proper approach of equipment
• Learn skills to inspect principal functions and parts comprising equipment
• Thoroughly inspect principal functional parts comprising equipment and actualize and restore latent
defects
Preparations
• Cut model
• Inspection
item list
• Flow chart
• Schematic
diagram
Training implementation
© Identify subjects
© Prepare teaching materials
© Prepare training program
© Instructors
© Leaders
© Each machine element 6 subjects
- 2 subjects
General inspection implementation
8. Machining conditions
7. Safety
6. Electric
5. Drive
4. Pneumatic
3. Hydraulic
Inspection
2. Lubrication
Analysis of
results
1. Bolts and nuts
Training
Prepare 1- point lessons
Transmission of education
General inspection manual
Comprehension check
Skill check
Prepare tentative inspection standard for
each subject
Restore and
improve
© Visual control
Items pointed
out
Autonomous audit for each subject
Plant audit for each subject
Circle activity report
Application for plant audit
See data for
each subject
•………
•………
Hydraul
ic
fuguai
Activities board
Passed
© JIPM, 1987