INTERNATIONAL COLLEGE OF AUTOMOTIVEDIPLOMA IN AUTOMOTIVE MANAGEMENT SYSTEM

GROUP PRACTICAL

GROUP NUMBER :GROUP 4

GROUP MEMBERS NAME : 1. Mr. Amir Bin Haridan ( EDMS -1004 - 00000027 ) 2. Mr. Mohd Azhar Bin Mohd Yusof ( EDMS -1003 - 00000017 )

3. Mr. Mohd Shaid Bin Ghazali ( EDMS -1003 - 00000008 ) 4. Mr. Muhammad Shamsudin Bin Jahaya ( EDMS -1004 - 00000030 )

5. Mr. Muhammad Faizal Bin Satar ( EDMS -1003 - 00000010 )

MODULE : MMS 1063 - AUTONOMOUS MAINTENANCE SEMESTER : 3

TITLE : CORRECTIVE ACTION AND KAIZEN REPORT

GROUP PRACT. NO : 4

LECTURE : Mr. Azam Bin Musa

MARKS : __________________________

1. Introduction Fuguai detection Source and contamination Difficult Area.

2. Fuguai Detection List3. Source and Contamination List4. Difficult Area list5. Problem Definition6. Containment Action7. Root Cause Analysis8. Why-Why Analysis9. Corrective Action

Corrective Action 1 ~ 4

10. Verification11. Preventive Action12. KAIZEN13. Conclusion

Contents

Automation become popular among Japanese manufacturers. Automation eliminates drudgery manual labor, improves the quality and reduces cost.

The uniqueness of AM is that the maintenance is carried by the Production department. The success of TPM depends on upon the success of the Autonomous Maintenance Program.

Introduction

Fuguai ListNo Location Photo Fuguai Tag Tag

TypeOptional Action P.I.C Date

1 Inside Front Dusty at area and light not function Blue Tag

Clean the dusty and check light to make sure the function ok

Prepare cleaning checklist and change new bulb

Shaid

11/5/2011

2 Front Side The door not tightly closed and a lot chip in this area. Red Tag

Tightly all nut at the door and cleaning all chip

Prepare fastener checklist

Shamsudin

9/5/2011

3 Right Side The door not tightly closed and there area lot at chip. Red Tag

Tightly all nut at the door and cleaning all the chip

Prepare fastener checklist

Faizal

7/5/2011

4 Inside Front Cover crack source a lot chip in this area. Red Tag

Change new transparent cover and cleaning all chip

Change new transparent cover

Azhar

10/5/2011

5 Back Side There are a lot chip and oil in this area. Blue Tag

Cleaning all chip and check the oil hose if licking change the hose

To provide Maintenance Checklist schedule

Amir

8/5/2011

Fuguai ListNo

Location

Photo Fuguai Tag Tag

TypeOptional Action P.I.C Date

6Back Side

There are a lot chip in this area.

Blue Tag

Wipe and clear all chip

To Update cleaning Checklist

Shaid

11/5/2011

7Back Side

there are a lot of dust, chip and oil in this area.

Blue Tag

Use cotton rag, water and soap to clean dust and oil.

To Update cleaning Checklist

Samsudin

9/5/2011

8Front Side

Cover transparent not clear.

Blue Tag

Change the new cover transparent.

To Change New Transparent cover Faizal

7/5/2011

9Front side

Panel switch button a lot dust and oil.

Blue Tag

Use cotton rag to clean dust and oil.

Provide Cleaning Checklist

Azhar

10/5/2011

10Right Side

There are a lot chip ,dust and oil in this area.

Blue Tag

Use cotton rag,water,soap and air gun to clean and clear dust, chip and oil.

Provide Cleaning Checklist

Amir

8/5/2011

Source of contaminantsNo Location Photo

Source Of Contaminants

Tag Type

Optional Action P.I.C Date

1 Front Side

Cover broken not protect from dust, oil and chip.

Red Tag

Change new

cover

To Change new

transparent cover Shaid

11/5/2011

2 Front Side

No cover to protect from dust, chip and oil.

Blue tag

Provide transparent cover

To Install new

transparent cover Shamsudin

9/5/2011

3 Left SideCover

transparent left side not clear.

Blue Tag

Change new

cover

To Change new

transparent cover Faizal

7/5/2011

4 Front SideCover transparent not clear.

Blue Tag

Wipe transparent cover

To Prepare cleaning checklist

Azhar

10/5/2011

5 Back sideWiring not

proper.Red Tag

Make proper wiring

Prepare S.O.P

Amir

8/5/2011

Difficult areasNo Location Photo Difficult

AreasTag

Type Optional Action P.I.C Date

1 Inside Left

Narrow place to be clean.

Blue tag

Take time to

cleaning and

careful

Prepare Cleaning

S.O.PAzhar

11/5/2011

2Inside Front

Narrow place to be clean.

Blue Tag

Take time to

cleaning and

careful

Prepare Cleaning

S.O.P

Shaid

9/5/2011

3 Inside Left

Sensitive area and narrow place to be clean.

Red Tag

Take time to

cleaning and

careful

Prepare Cleaning

S.O.P

Shamsudin

7/5/2011

CNC MACHINE

HYDRAULIC PUMP ( OIL SEAL LEAKING)

PROBLEM

Machine Problem

MC 1 MC 2

LOCATIONPROBLEM

STATEMENTAREA VISUAL

1.Operator was found oil leaking during production at shop floor.

2.Problem happens after 4 hours machine run the production

Problem Definition

1. Stop Production

2. Off machine

3. Close the main source of oil pump hydraulic to avoid too much oil spill

4. Wipe the leaking oil

5. Inform the leader

PUMP HYDRAULICSTEPS

Containment Action

PIC

AMIR HARIDAN

Ishikawa diagram

VALVE PLUGGED UP

OIL SEAL LEAKING

OPERATOR NOT ALERT DURING RUN

THE PRODUCTION

LACK OF SKILL

MAN

METHOD

MACHINE

MATERIAL

SPARE PART PROBLEM

MAINTENANCE CHECK SHEET NOT

PROPER

HYDRAULIC PUMP

LEAKING

PARAMETER PRESSURE NOT FUNCTION

WRONG PARAMETER OIL PRESSURE

Root Cause Analysis

LEGENDTRUE PROBLEMFALSE PROBLEM

causes why1 why2 why3 why4 why5

Operator not alert during

run the production

Knowledge about machine

poorno experience New worker No training

Oil sealleaking

Oil seal insulator torn Old oil seal

No maintenance

No schedule No PIC

wrong parameter air

pressure

Operator not check before

run the machine

No standard manual for air

pressure Not provided

by engineering

spare part problem Quality poor

Not followed specification

5 WHY analysis

Why-Why Analysis

PIC: SHAIDDATE: 11/5/2011

CAUSES CORRECTIVE ACTION

operator not alert during run the production

1. Provide on job training to all new employee2. Provide training3. Remain to all operator to ensure machine in good

condition before run the machine(morning assembly)

Oil seal leaking 1. Provide maintenance check sheet and schedule2. Put PIC

wrong parameter air pressure 1. Provide automatic air pressure2. Always check the air pressure before run the production

spare part problem 1. Refer to supplier why quality of part poor2. Buy the good quality spare parts

Corrective Action

PIC: FAIZALDATE: 11/5/2011

ACTION SAMPLE TRAINING CHECKSHEET

1. provide on job training to all new employee

2. provide training3. remain to all operator to ensure machine

in good condition before run the machine(morning assembly)

Corrective Action 1

AZHAR

SUDIN

BOB

SHAID

PIC: AZHARDATE: 11/5/2011

ACTION SAMPLE MAINTENANCE CHECKSHEET

1. Provide maintenance check sheet and schedule

2. Put PIC

Corrective Action 2

PIC: SHAIDDATE: 11/5/2011

ACTION SAMPLE AIR PRESSURE MANUAL

1. Provide automatic air pressure

2. Always check the air pressure before run the production

Corrective Action 3

PIC: FAIZALDATE: 11/5/2011

ACTION SAMPLE INSPECTION SHEET

1. Refer to supplier why quality of part poor.

2. Buy the good quality spare parts.

Corrective Action 4

PIC: AZHARDATE: 11/5/2011

Verification

IMPROVEMENT REPORTAction: Change new oil

sealVerify by: Abu Bin AliDate:11th May 2011Sign:………………………….Approve by: Ali Bin BakarSign:………………………….(Head of Maintenance)

FORM PICTURE

PROBLEM PREVENTIVE ACTION

Operator not alert during run the production

1. Training to all employee every week2. Monitoring operator knowledge and skills

(skill chart)

Oil seal leaking1. Provide maintenance thrice a year2. Monitoring every time machine

performance

Wrong parameter air pressure1. Monitoring the air pressure during run the

production

Spare part problem

1. Do the inspection for incoming parts from supplier

2. Buy parts high quality

Preventive Action

PIC: SHAMSUDINDATE: 11/5/2011

KAIZEN

HMS DIV.HEAD DEPT. HEAD SECTION HEAD PREP. BY

En.Shukri En.Azalan En.Azam En.Nadzrul Shaid

PROPOSED BY Mohd Shaid Bin Ghazali LOCATION IMPLEMENTATION Distribution box

KAIZEN NAME Application Conduits wire and cable tie DATE IMPLEMENTATION 15 May 2011

PROBLEM COUNTERMEASURE RESULT

Hydraulic pipe leaking due to oil seal broken.

Change the heavy duty oil seal.

No oil leaking and easy to cleaning.

BEFORE AFTER

GEMBA KAIZEN REPORT

REPORT NO: EDMS-1003-008/11

HMS DIV.HEAD DEPT. HEADSECTION

HEADPREP. BY

En.Shukri En.Azalan En.Azam En.Nadzrul Shaid

PROPOSED BY Mohd Shaid Bin Ghazali LOCATION IMPLEMENTATION Motor bending machine

KAIZEN NAME Provided transparent cover DATE IMPLEMENTATION 5 April 2011

PROBLEM COUNTERMEASURE RESULT

Dust covers the hydraulic motor.

Fabricate new transparent cover to protect from Dust.

No more cleaning activity at cover area and easy to inspection.

BEFORE AFTER

GEMBA KAIZEN REPORT

REPORT NO:EDMS-1003-009/11

With Transparent cover

Without Transparent cover

KAIZEN

Every step in Autonomous Maintenance is very important to ensure all activities to smooth running.

The most important to identify of a basic AM is a fuguai, source contamination, difficult areas and how people involve in all activities.

When AM activities are done according to the schedule, the machines life will long lasting, high quality, and will improve the production furthermore reduce the cost.

Conclusion