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JISHU HOZEN is TPM pillar, Not complete slides
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1Eight Steps in JISHU HOZEN
JISHU- HOZEN Prevent the occurrence of 1A/1B because of JH.
Reduce the OIL consumption by 50%.Reduce Process time by 50%.Increase use of JH by 50%
1. Prep of Employees2. Initial Cleanup of Machine
3. Take Counter Measures
4. Fix Tentative JH Stds5. General Inspection
6. Autonomous Inspection7. Standardization8. Autonomous Management
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
2
JISHU- HOZEN
1. Initial Cleaning and Tagging
2. Counter Measures against Source & Kaizen
3. Develop Tentative Standards
Autonomous Maintenance7 steps
4. General Inspection5. Autonomous Inspection
6. Standardization7. Autonomous Management
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
3
JISHU- HOZEN
1. Manage Model Team
2. Manage Model Machine
3. Implement 5S
Autonomous Maintenance
PROCESS
4. STEPS 123
5. Kickoff
6. Forms Autonomous Maintenance Teams
7. Steps 123 with Audits
8. Deployed to other M/C
9. Go to Step 4&5 and continue
1. Initial Cleaning and Tagging
2. Counter Measures against Source & Kaizen
3. Develop Tentative Standards4. General Inspection
5. Autonomous Inspection
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
4
JISHU- HOZEN
4. Setup & Adjustment Loss
6. Defect Quality Loss
5. Yield Loss
WHY Autonomous Maintenance
7. Poor Skills of Operator
3. Breakdown Loss
1. Minor Stoppage Loss2. Reduced Speed Loss
8. Improper Position to Conduct Inspections
Preventive Maintenance
Production Maintenance
TPM
American Style of PMJapan Style of PM
Maintenance Departments Sole Responsibility
9. Confirmation of working conditions10. Daily Inspection / Periodical Inspection
10. Activities to prevent eqpt degradation
11. Activities to keep record on eqpt degradation
12. Keep cleaning, Inspection, Additional light
13. Activities to restore the machine conditions
14. Frequent Servicing, Solution of abnormality, Good Communication
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
5
WHYJISHU- HOZEN
5. To eliminate equipment failure
6. To eliminate quality defect
2. To make operator familiar with his equipment
7. To eliminate cost losses
1 To establish basic equipment condition
3. To prevent equipment deterioration4. To maintain in optimal condition
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
6
JISHU- HOZEN
1. Indl preserving one’s own eqpt
The Mind Set
2. Significant Change from early theory of “ I mfr - U Repair” or “ I make – U Fix”
Production indls Thoughts Maintenance indls Thoughts
Maint does NOT its Job Production do not know how to operate
Maint staff take took long to fix job We get lot of repairs so we don’t have ample to do a Real corrective and are forced to do only temporary jobThis eqpt is so OLD no wonder it breaks
down again & againWe are too busy to do vital daily checks We Prep the stds but they do not do the
checks
7
JISHU- HOZENThree Key Tools for Autonomous Maintenance
Activity Board
One Point LessonMeetings
Key Concepts:Shop Floor Based ActivitiesOperator ConductedOperator EnhancingTeam Activity Autonomous ManagementTPM FoundationPart of the Job
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
8
JISHU- HOZENThree Key Tools for Autonomous Maintenance
Activity Board
People Activity & Findings Treasures
Team & Team Mission Step1- initial Cleaning
Display Actual Findings from initial cleaning, such as Trash, Unnecessary Items, Dust and other contamination
Line Layout & identified important areas
-Definition-Pics before / after
Step 2- Source of Contamination“ Explain & show Focused Improvement activities for Source of Contamination”
-Safety Hazard- Contamination- Hard –to - Reach- Maint Failure
- Tag List Production/ Maintenance- Tag Movement / Actual tags
One Point Lesson
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
9
JISHU- HOZENThree Key Tools for Autonomous Maintenance
Activity Board
Dept / Line: Bldg Y
Area: Bag Printer
Mach ID Date: 4/28 /14
Tag
Diagram No. Items Criteria Method Tools T(Min) Freq Person Resp
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
10
JISHU- HOZENThree Key Tools for Autonomous Maintenance
One Point Lesson
One Point Lesson is a tool with the Following Characteristics:
1. One Sheet2. To Share the results of autonomous
study3. For 5-10 minutes
Contents can be knowledge and skills of
1. Equipment2. Safety3. Operation Process4. Task
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
11
JISHU- HOZENEquipment
Deterioration
ACCELERATED Deterioration(Eliminate Cause)
Natural Deterioration(Extend Life Time)
Corrective MaintenancePrevent errors by IMPROVING Operability & Repair QualityImprove Maintainability & Repair QualityImprove Safety & Reliability
Establish Basic ConditionsCleaning : Eliminate all dust & DirtLubricating : Keep lubricants clean and replenished.Tightening: Keep Nuts & Bolts secure
12
JISHU- HOZENClassification of Maint Activities
C. Activities to Rectify deteriorationBy improving reliability,
maintainability of machines (MTBF, MTTR)
A. Activities to prevent deteriorationBy correct operation , improvement of basic conditions & adjustments to prevent quality defects.
B. Activities to MEASURE deteriorationBy Senses (touch, see, hear, smell)
Role of Production Role of Maintenance
-Play vital role in A. also records maintenance data for prevention of recurrences of problems & MP design.- Play role in B by five senses-Play role in C by prompt reporting & assisting in sporadic failure.
-Play role in as a guide & educationist & providing help in identifying areas “ sources of problems & “Hard to Clean”- Play in role B by vibration & fluid analysis.- Play major role in C by improving MTBF, MTTR.-Besides that they maintain MIS , work for new equipment design & setup maintenance stds.
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
13
JISHU- HOZENSTEP - 0
1. Prep a Cleaning & Lubrication Map
Initial Preparation
. Prep of JH Activities
2. Arrange Tools
3. Arrange Red & White Tags
4. History of Failures
5. Training on 7 Steps of Jishu Hozen
6. Gant Chart
7. Training on 7 Types of abnormalitiesPrep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
14
JISHU- HOZENSTEP - 1
2. Use 5 Senses for Cleaning
Initial Cleaning
1. Cleaning is Inspection
3. Find out 7 Types of Abnormalities
4. Put Tags on Abnormalities
5. Make the List of
Hard to CleanHard to LubricateHard to TightenHard to InspectHard to Adjust
Record cleaning timeCarryout Audit on 1st StepMeeting after the Daily ActivitiesRefers to the Old History Records
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
15
JISHU- HOZENSTEP - 1 Initial Cleaning – 7 Types of Abnormalities
2. Places
In Accessible Unsafe
2. Sources
ContaminationQuality Defect
1. Items
Un-necessary – Non Urgent
1. Minor Flaws
1. Unfulfilled Basic Conditions
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
16
JISHU- HOZENSTEP - 1 Initial Cleaning – 7 Types of Abnormalities
1.Minor Flaws
Contamination
Damage
Adhesion
Abnormal Phenomenon
Blocking, Hardening, Accumulation of Debris, Peeling, Malfunction
Dust, Dirt, Powder, Oil, Grease , Rust, Paint
Play
Slackness
Bending, Cracking, Crushing, Chipping, Deformation
Shaking, Falling Out, Tilting, Eccentricity, Wear, Distortion, Corrosion
Belts, Chains
Unusual Noise, Overheating, Vibration, Strange Smells, Discoloration, Incorrect Pressure or Current
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
17
JISHU- HOZENSTEP - 1 Initial Cleaning – 7 Types of Abnormalities
2.Unfulfilled Basic Conditions
Lubrication
Lubrication Supply
Dirty, Insufficient, Unidentified, Unsuitable, Leaking
Oil Level Gauges
Tightening
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, Unsuitable washers, wing nuts on backward
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
18
JISHU- HOZENSTEP - 1 Initial Cleaning – 7 Types of Abnormalities
3. Inaccessible Places
Clean
ing
Chec
king
Adjus
tmen
t
Opera
tion
Position of Pressure Gauge, Thermometers, Flow Meters, Moisture Gauges, Vacuum Gauges etc.
Machine Construction, Covers, Layout, Footholds, Space
Lubr
icating
Tight
enin
g
Construction, Covers, Layout, Footholds, Instrument position and Orientation, Operating – Range Display
Position of Lubricant Inlet, Construction, Height, Footholds, Lubricant outlet, SpaceCovers, Construction, Layout size, Space
Machine Layout, Position of Valves, Switches and Leavers, Footholds
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
19
JISHU- HOZENSTEP - 1 Initial Cleaning – 7 Types of Abnormalities
4. Unsafe Places
Floors
Steps
Others
Lifting Devices
Special Substances, solvents, Toxic gases, Insulating materials, danger signs, protective clothing etc.
Unevenness, cracked, holes, projections, peeling, wear of steel chucker plates, slipping.
Lights
Rotating Machinery
Too steep, irregular, slipping, missing Hand rails
Dim, out of Position, dirty / broken covers,, no explosion proofing etcDisplaced, Fallen oil / broken covers, not safe for emergency, Missing emergency stop Devices
Wires, Hooks, Brakes & Other parts of cranes and Hoists
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
20
JISHU- HOZENSTEP - 1 Initial Cleaning – 7 Types of Abnormalities
5. Contamination Sources
Product
Raw Materials
Others
Liquids
Contamination by people & Forklifts, Infiltration through cracked walls, broken windows etc.
Leaks, Spills, Spurts, Scattering, Overflow
Lubricants
Gases
Leaks, Spills, Spurts, Scattering, Overflow
Leaking, Spills, Seeping Oils, Hydraulic Fluids, Fuel Oils
Leaking compressed air/gases/steam/vapors/exhaust fumes
Leaking Water/hot/cold, Half Finished Products, waste Water, Leaking Supply lines
Scrap Flashes, Cuttings, Packaging material and NC Products
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
21
JISHU- HOZENSTEP - 1 Initial Cleaning – 7 Types of Abnormalities
6. Quality Defect Sources
Foreign Matter
Shock
Viscosity
Concentration
Inadequate Warming, Heating, Compounding, Mixing, Evaporating, Stirring etc.
Dust, Rust, Powder, chips, Moisture, Wire scraps, Wood Pieces, Paper pieces, stones etc.
Moisture
Gain Size
Dropping, Jolting, Collision, Vibration etc.
Too little or Too Much, Infiltration
Abnormalities in Screens, Compressed air separators, Centrifugal Separators
Inadequate Warming, Heating, Compounding, Mixing, Evaporating, Stirring etc.
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
22
JISHU- HOZENSTEP - 1 Initial Cleaning – 7 Types of Abnormalities
7. Un-Necessary and Non Urgent Items
Machinery
Piping Equipment
Spare Parts
Jigs & Tools
Standby eqpt, spares, permanent stocks, Auxiliary material
Pumps, Fans, Compressors, Columns, Tanksers
Measuring Instruments
Electrical eqpt
Pipes, Hoses, Ducts, Valves, Dampers etc.
Temperatures, Pressure Gauges, Vacuum Gauges, Ammeters etc
Wiring, Piping, power leads, Switches, Plugs etc.
Gen Tools, Cutting Tools, Jigs, Molds, Dies, Frames etc.
Makeshift Repairs Tape, String, Wire, Metal plates etc.
23
JISHU- HOZENSTEP - 2 Measure Against Sources
Counter Measure Against Source of Contamination & Hard to do CLRI
Ranking the priority places for daily cleaning
Counter Measure against source of contamination
Make approach easy for CLRI.
Make easy to do CLRI
Shorten, Cleaning & lubricating time.
Adopt concepts of localized guards.
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
24
JISHU- HOZENSTEP - 3 Formulation of Cleanup and Lubrication Standards
Prepare Tentative Standards
Standards for Cleaning, Lubricating & Tightening
Standards are made by Operators themselves with guidance by PM
Standards are Made by using 5W 1h
Standards should be Easily understood by every one
Introduce Extensive Visual Control.
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)