autonomous maintenance

1

Dr. Hajime YamashinaProfessor Emeritus, Kyoto UniversityMember of RSA (U.K.)Member of Royal Swedish Academy of Engineering Sciences (Sweden)

Autonomous Maintenance

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1. Introduction2. Expected Abilities of Operators3. Promote AM Step by Step4. Autonomous Maintenance5. Audit Criteria and the Check List of Autonomous M

aintenance6. Three Key Points for Successful Small Group Acti

vities7. Roles of Operators and Maintenance PeopleAppendix : Examples of One Point Lessons

Autonomous Maintenance

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1. Introduction

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• A machine breakdown does not occur suddenly. There is a symptom of the breakdown before it takes place. That is, it is the result of the growth of a minor defect. • To eliminate breakdowns, it is necessary to check equipment for detecting a symptom of a breakdown.• Maintenance crew cannot detect and cover all the symptoms of breakdown.• It is the operators of machines and processes who can catch the information on the status quo of an item of plant and prevent it from breaking down.

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1

• Unless the operators know how to maintain equipment, they cannot help having equipment breakdowns.• AM is powerful in case where there are operators and where breakdowns, defectives and minor stoppages take place due to lack of maintaining the basic condition of equipment and when they inspect their equipment.

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Tota

l num

ber

of b

reak

dow

ns PM

PM(AM)

Lack of the basic conditions

Including

Human

errors

• In general, one third of breakdown comes from lack of basic conditions.

• Another one third of them can be avoided if the competence of AM people can be raised and AM step 1 – step 7 are carried out rigorously with well organized inspection of natural deterioration, but this costs much money.

• The rest can be tackled by PM step 1 – step 3. Once we establish a PM calendar, we understand what we have to do with the equipment.

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2. Expected Abilities of Operators

2.1 Abilities to Understand Process Performance and Functions and Operate Process Correctly2.2 Abilities to Understand Properties of Materials Being Handled and Perform Correct Adjustment and Setting2.3 Abilities to Detect Abnormalities Promptly and Take Emergency Action Against Abnormalities2.4 Abilities to Recognize Signs of Abnormality, Deal with Abnormalities Correctly and Perform Periodic Overhaul Checking and Parts Replacement Correctly2.5 Four Steps Capable Operators

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Abilities to Understand Process Performance and Functions and

Operate Process Correctly

It's easy to see results.

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What do we have her e, a l i t t l e f l aw?

Devel op an eye f or sl i ght abnor mal i t i es

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Anot her day wi t h no br eakdowns and no def ect s!

Ever yt hi ng’ s i n per f ect wor ki ng condi t i on t oday!

Al l c l eaned and oi l ed!

Br eak-

downs

Def ect s Pr oduc-

t i v i t y

•Thi nk syst emat i cal l y!•Act syst emat i cal l y!

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I t must be a l oose bol t t hat ’ s causi ng t he vi br at i on.

No, you’ r e wr ong!

Ther e’ s a wor n bear i ng

you shoul d check!

Abi l i t i es t o Under st and Pr oper t i es of Mat er i al s Bei ng Handl ed and

Per f or m Cor r ect Adj ust ment and Set t i ng

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The vibrationof the motoris too big ! the vibration

of the motor occurredbecause ofloose nuts.

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I can sense abnormality !

No, according to my experience, it's normal ! abnormal

normal checkpoint

checkpoint

checkpoint

Abi l i t i es t o Det ect Abnor mal i t i es Pr ompt l y and Take Emer gency Act i on Agai nst Abnor mal i t i es

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Abilities to Recognize Signs of Abnormality, Deal with Abnormalities Correctly and Perform Periodic Overhaul Checking and Parts Replacement Co

rrectly

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Four Steps Capable Operators

1. Under st ands pr ocess per f or mance and f unct i ons and oper at e pr ocess cor r ect l y

2. under st ands pr oper t i es of mat er i al s bei ng handl ed and per f or m cor r ect adj ust ment and set t i ng

3. det ect s abnor mal i t i es pr ompt l y and t ake emer gency act i on agai nst abnor mal i t i es

4. r ecogni zes si gns of abnor mal i t y, deal wi t h abnor mal i t i es cor r ect l y and per f or m per i odi c over haul checki ng and par t s r epl acement cor r ect l y

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Step 1: The operator can detect problems and understand the principles and the procedures of equipment impr

ovement.

Don' t l et t he machi ne get di r t y.

Make t he machi ne i n such a way as t o be easi l y checked.

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Structural diagram

Real l y know t he f unct i ons and st r uct ur e

of your equi pment .

St ep 2: The oper at or knows t he f unct i on and st r uct ur e of equi pment .

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Step 3: The operator knows the relationship between equipment accuracy and product quality.

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Step 4: The operator can repair equipment.

Mastering of Basic Skills

Properbolting

Centering ofpooleys andgears

Exchange ofbearings

Prevention ofoil leakage

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３３ Promote AM Step by Step

3.1 The Seven Steps of AM

3.2 The Four Steps to Capable Operators and the Seven Steps of AM

3.3 Developing an Autonomous Maintenance Program

3.4 The Goals of AM

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Step 7

Initial cleaning

Fully implemented autonomous management

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

Countermeasures against sources

Tentative standards

General inspection

Autonomous inspection

Workplace organization and housekeeping

Challenge this step and find benefits.

Reactive Preventive Proactive

The Seven Steps of AM

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Promote autonomous maintenance step by step

• Provide inspection skills training based on inspection manuals

• Get individual equipment items into peak condition by subjecting them to general inspection

• Modify equipment to facilitate checking. Make extensive use of visual controls

4. Conduct general equipment inspection

• Formulate work standards that help maintain cleaning, lubricating, and tightening levels within minimal time and effort

• Improve the efficiency of checking work introducing visual controls

3. Establish leaning and checking standards

• Reduce housekeeping time by eliminating sources of dust and dirt, preventing scatter, and improving parts that are hard to clean, check, lubricate, tighten, or manipulate

2. Address contamination sources and inaccessible places

• Eliminate dust ant dirt from main body of equipment• Expose irregularities such as slight defects, contamination sources, inaccessible places, and sources of quality defects

• Eliminate unnecessary and seldom-used items, and simplify equipment

1. Perform Initial cleaning

ActivitiesStep

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Step Activities

5. Perform general process inspection

•Provide instruction in process performance, operation, and adjustment and in methods of handing abnormalities in order to improve operational reliability by developing process-competent operators

•Prevent inspection duplications and omissions by incorporating provisional cleaning and inspection standards for individual equipment items into periodic inspection and replacement standards for entire processes or areas

6. Systematize autonomous maintenance

•Achieve quality maintenance and safety by establishing clear procedures and standards for dependable autonomous maintenance

• Improve setup procedures and reduce work-in-process•Establish a system of self-management for work place flow, spares, tools, work-in-process, final products, data, etc.

7. Practice full self-management

•Evolve activities and standardize improvements in line with company and plant policies and objectives, and reduce costs by eliminating work place waste

• Improve equipment further by keeping accurate maintenance records (e.g., MTBF) and analyzing the data in them

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Practice full self-management

Production based on the given schedule (focus : production)

Recognizes signs of abnormality; deals with abnormalities correctly; performs periodic overhaul checking and parts replacement correctly

Systematic autonomous maintenance

Quality assurance (focus : process)

Detects abnormalities promptly; takes emergency action against abnormalities

Perform general process inspection

Management of deterioration and restoration (focus : machine 　 to process)

Understands properties of materials being handled; performs correct adjustment and settingConduct general

equipment inspection

Establish cleaning and checking standards

Basic conditions to prevent deterioration (focus : machine)

Understands process performance and functions; operates process correctlyAddress contamination sources

and inaccessible places

Perform initial cleaning1

2

3

4

5

6

7

1

2

3

4

The Four St eps t o Capabl e Oper at or s and t he Seven St eps of Aut onomous Mai nt enance

25

The Five Levels of Operators

• Operation only• Multi-operations• 2 + QC + AM• 3 + Improvement• 4 + Engineering

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Autonomous maintenanceØ When equipment does not have the basic condition to be operated and there are many possible causes which may lead to breakdowns, a collective approach by AM without persistently asking why, why, - - - to identify root causes, can work well. But when there are few breakdowns, AM can be very costly.

Ø Step 2 is the key to get the benefits of AM.

Ø Applying AM Step 1 – 3 is the key to establish the basic condition of the equipment.

Ø The major economic benefit of AM can be gained by AM Step 1 – 3.

Ø Step 4 costs time and money.

Ø Depending on the breakdown situation of the equipment applying Step 4 cannot be economically justified.

Ø We need to add something extra activities on Step 4 to get benefits out of it.

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Autonomous maintenanceØ When equipment does not have the basic condition to be operated and there are many possible causes which may lead to breakdowns, a collective approach by AM without persistently asking why, why, - - - to identify root causes, can work well. But when there are few breakdowns, AM can be very costly.

Ø Step 2 is the key to get the benefits of AM.

Ø Applying AM Step 1 – 3 is the key to establish the basic condition of the equipment.

Ø The major economic benefit of AM can be gained by AM Step 1 – 3.

Ø Step 4 costs time and money.

Ø Depending on the breakdown situation of the equipment applying Step 4 cannot be economically justified.

Ø We need to add something extra activities on Step 4 to get benefits out of it.

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Two characteristic keys to developing a successful autonomous maintenance program are :

• thoroughness• continuity

Actual decisive factor is smooth integration with the following two WCM fundamental activities :

• focused improvement to create know-how to attack waste and losses systematically

• education and training to horizontally expand the know-how created by focused improvement

Developing an Autonomous Maintenance Program

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• Prevent equipment deterioration through correct operation and daily checks

• Bring equipment to its ideal state through restoration and proper management

• Establish the basic conditions needed to keep equipment well-maintained

The Goals of AM

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4. Aut onomous Mai nt enance

4. 1 Why i s Aut onomous Mai nt enance Necessar y?

4. 2 The Ai m of AM4. 3 St ep 0 : Pr el i mi nar y Act i vi t i es4. 4 St ep 14. 5 The Basi s of Aut onomous Mai nt enance i s

I ni t i al Cl eani ng.4. 6 The I mpor t ance of Cl eani ng 4. 7 Put a Label Wher e Ther e i s Somet hi ng

Wr ong.4. 8 The I mpor t ance of I nspect i on4. 9 The I mpor t ance of Lubr i cat i on4. 10 Est abl i sh t he Basi c Equi pment

Condi t i ons

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Why is Autonomous Maintenance Necessary?

Activities to measure

deterioration

Activities to prevent

deterioration

Activities to restore

deterioration

* Checking of operating condition* Daily checking* Periodical checking

* Minor adjustment* Taking measures against abnormalities* Reporting the abnormality to the maintenance department

* Cleaning* Inspection* Bolting

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Funct i onal el ement

Funct i onal par t Tr oubl e Cause

1. Lubr i cat i on Lubr i cat i on oi l , gr ease

Sei ze Lack of l ubr i cat i on oi l ,

I mpr oper oi l

2. Bear i ng Bal l , Rol l er , Pl ai n bear i ng

Sei ze, Vi br at i on Lack of l ubr i cat i on oi l , Over l oad, Eccent r i c i t y

3. Body of r ot at i on

I mpel l er , Rot or Shaf t sei ze, Vi br at i on

Unbal ance

4. Connect i on Coupl i ng, Gear , Key

Br eakage, Vi br at i on

Eccent r i c i t y, negl ect ed wear

5. Tr ansmi ssi on V bel t , Chai n, Cl ut ch

Sl i di ng, Heat Negl ect ed wear

6. Seal i ng Packi ng, Seal i ng mechani sm

Leakage, Expl osi on, Fi r e

Negl ect ed wear , i nsuf f i c i ent f ast eni ng

7. Dust pr ot ect i on

Fi l t er st r ai ner Bl ocki ng Lack of c l eani ng, Damaged el ement

8. Fl ui d cont r ol Pi pe, Val ve, Or i f i ce

Abnor mal pr essur e, Cl oggi ng, Abnor mal quant i t y of f l ow, Leakage

Negl ect ed f or ei gn body

9. Fast eni ng Bol t , Nut , Fl ange, Pi n, Rot or

Vi br at i on I nsuf f i c i ent f ast eni ng

10. I ndi cat i on Pr essur e gauge, I nst r ument

Temper at ur e, pr essur e, Abnor mal qual i t y of f l ow

Cl ogged, I nsuf f i c i ent checki ng

11. Mai n body Pump, Compr essor Vi br at i on, Leakage

Damage, I nsuf f i c i ent f ast eni ng

Functional elements and their troubles

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Ai m of AM

•The ai m i s t o hel p t he oper at or t o devel op hi msel f . I t wi l l be done i n smal l s t eps. See bel ow t o see how he can go about hi msel f devel opment t r ai ni ng.

Self teaching in classroom

While seeing teaching material (actual article) using texts

Group discussion

Doubt, group discussion of

tasks, Instructors ask questions

Practice

Show by self what has been

learnt

Discussion of results and supplementary lecture

Group discussion, Instructors supplement lecture

Practice

Practice of normal work method.

Instructors correct.

Discussions of results and supplementary lecture

Group discussion and discussion by all supplementary lecture

The Aim of AM

34IVECO PRODUCTION SYSTEM

AUTONOMOUS MAINTENANCEWORLD CLASS MANUFACTURING AUDITValladolid Plant, may 2008

STEP 0 – Preliminary Activities

Step 0

2. Initial Workshop, Model Areas

3. Team’s Basic Training

Step 0

4. Activity Plan

5. Preparation Activities

1. Permanent Team

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Step 0: Model Area

2) EQUIPMENT CLASSIFICATION

1) COST DEPLOYMENT

MODEL AREA

MODEL AREA AUTONOMOUS MAINTENANCE SETTING

‘AA’ CLASS EQUIPMENT

WITH MAJOR LOSSES DUE ON COST DEPLOYMENT

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Reactive Preventive Proactive

AA Very big losses based on cost deployment

Very big possible losses

Very big potential losses based on financial risk deployment

A Big losses based on cost deployment

Big possible losses Big potential losses based on financial risk deployment

B Some amount of losses based on cost deployment

Some amount of possible losses

Some potential losses based on financial risk deployment

C Small losses based on cost deployment

Small possible losses Small potential losses based on financial risk deployment

AM* To start : Definition of machine related waste and losses and their measurement (OEE, OPE)

* Root causes : Lack of the basic conditions

* Classification of machines

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C matrix: K€ guasti / UTE

0

100

200

300

400

500

600

700

800

900

208 222 203 207 205 202 204 201 223 221

UTE

k€/a

nn

o

C matrix: breakdowns losses/ute

D matrix

Link to cost deployment

D MATRIXBreakdown analyzed by EWO format

0

100

200

300

400

500

600

700

800

900

208 222 203 207 205 202 204 201 223 221UTE

k€/Y

PD

FI

PM

AM

AM

38

0

1

2

3WCM

METODO AM(7 STEP)

AM TAGS

5 WHYS

OPL

EQU. ABC CLASSIF.

altriTOOLS

(kaizen, 5S, Poka Yoke, 5W1H)OEE

Conosce nza processo

Gestione ciclo

Cambio tipo

Procedure di ripristino

Attrezzamento

0

1

2

3

WCM

METODO AM(7 STEP)

AM TAGS

5 WHYS

OPL

EQU. ABC CLASSIF.

altriTOOLS


Conoscenza processo

Gestione ciclo

Cambio tipo


Attrezzamento

Team

0

1

2

3WCM

TPM

METODO AM(7 STEP)

AM TAGS

5 WHYS

OPL

EQU. ABC CLASSIF.

altriTOOLS

(kaizen, 5S, Poka Yoke, 5W1H)

OEE

Conoscenza processo

Gestione ciclo

Cambio tipo


Attrezzamento

Before training After training

0

1

2

3WCM

TPM

METODO AM(7 STEP)

AM TAGS

5 WHYS

OPL

EQU. ABC CLASSIF.

altriTOOLS

(kaizen, 5S, Poka Yoke , 5W1H)

OEE

Conoscenza processo

Gestione ciclo

Cambio tipo


Attrezzamento

0

1

2

3WCM

TPM

METODO AM(7 STEP)

AM TAGS

5 WHYS

OPL

EQU. ABC CLASSIF.

altriTOOLS


OEE

Conoscenza processo

Gestione ciclo

Cambio tipo


Attrezzamento

0

1

2

3

WCM

TPM

METODO AM(7 STEP)

AM TAGS

5 WHYS

OPL

EQU. ABC CLASSIF.

altriTOOLS

(kaizen, 5S, Poka Yoke, 5W 1H)

OEE

Conoscenza processo

Gestione ciclo

Cambio tipo

Proc edure di ripristino

Attrezza mento

Spidalieri Mengo

Aprile La Vigna

Iacobucci Caradonia

Colasanto Caiola

Di Nunzio

TEAM

0

1

2

3WCM

METODO AM(7 STEP)

AM TAGS

5 WHYS

OPL

EQU. ABC CLASSIF.

altriTOOLS

(ka izen, 5S, Poka Yoke, 5W1H)OEE

Conoscenza processo

Gestione ciclo

Cambio tipo


Attrezzamento

0

1

2

3

WCM

METODO AM(7 STEP)

AM TAGS

5 WHYS

OPL

EQU. ABC CLASSIF.

altriTOOLS


Conoscenza processo

Gestione ciclo

Cambio tipo


Attrezzamento

0

1

2

3WCM

METODO AM(7 STEP)

AM TAGS

5 WHYS

OPL

EQU. ABC CLASSIF.

altriTOOLS


Conoscenza processo

Gestione ciclo

Cambio tipo


Attrezzamento

0

1

2

3WCM

METODO AM(7 STEP)

AM TAGS

5 WHYS

OPL

EQU. ABC CLASSIF.altri

TOOLS(kaizen, 5S, Poka Yoke, 5W1H)

OEE

Conoscenza processo

Gestione ciclo

Cambio tipo


Attrezzamento

0

1

2

3WCM

TPM

METODO AM(7 STEP)

AM TAGS

5 WHYS

OPL

EQU. ABC CLASSIF.

altriTOOLS


OEE

Conoscenza processo

Gestione ciclo

Cambio tipo


Attrezzamento

Martino

0

1

2

3WCM

TPM

METODO AM(7 STEP)

AM TAGS

5 WHYS

OPL

EQU. ABC CLASSIF.

altriTOOLS


OEE

Conoscenza processo

Gestione ciclo

Cambio tipo


Attrezzamento

0

1

2

3WCM

TPM

METODO AM(7 STEP)

AM TAGS

5 WHYS

OPL

EQU. ABC CLASSIF.

altriTOOLS


OEE

Conoscenza processo

Gestione ciclo

Cambio tipo


Attrezzamento

0

1

2

3WCM

TPM

METODO AM(7 STEP)

AM TAGS

5 WHYS

OPL

EQU. ABC CLASSIF.

altriTOOLS


OEE

Conoscenza processo

Gestione ciclo

Cambio tipo


Attrezzamento

0

1

2

3WCM

TPM

METODO AM(7 STEP)

AM TAGS

5 WHYS

OPL

EQU. ABC CLASSIF.

altriTOOLS


OEE

Conoscenza processo

Gestione ciclo

Cambio tipo


AttrezzamentoSpidalieri Mengo

Aprile La Vigna

Iacobucci Caradonia

Colasanto Caiola

Di Nunzio

0

1

2

3WCM

TPM

METODO AM(7 STEP)

AM TAGS

5 WHYS

OPL

EQU. ABC CLASSIF.

altriTOOLS


OEE

Conoscenza processo

Gestione ciclo

Cambio tipo


Attrezzamento

0

1

2

3WCM

TPM

METODO AM(7 STEP)

AM TAGS

5 WHYS

OPL

EQU. ABC CLASSIF.

altriTOOLS


OEE

Conoscenza processo

Gestione ciclo

Cambio tipo


Attrezzamento

0

1

2

3WCM

TPM

METODO AM(7 STEP)

AM TAGS

5 WHYS

OPL

EQU. ABC CLASSIF.

altriTOOLS


OEE

Conoscenza processo

Gestione ciclo

Cambio tipo


Attrezzamento

0

1

2

3WCM

TPM

METODO AM(7 STEP)

AM TAGS

5 WHYS

OPL

EQU. ABC CLASSIF.

altriTOOLS


OEE

Conoscenza processo

Gestione ciclo

Cambio tipo


Attrezzamento

0

1

2

3WCM

TPM

METODO AM(7 STEP)

AM TAGS

5 WHYS

OPL

EQU. ABC CLASSIF.

altriTOOLS


OEE

Conoscenza processo

Gestione ciclo

Cambio tipo


Attrezzamento

Martino

40

St ep 1: Per f or m I ni t i al Cl eani ng• El i mi nat e di r t , dust , and gr i me

• Expose al l abnor mal i t i es

• Cor r ect mi nor f l ows and est abl i sh basi c equi pment condi t i ons

St ep 1

41

St ep1: Per f or m i ni t i al cl eani ng

Activities

• El i mi nat e dust ant di r t f r om mai n body of equi pment

• Expose i r r egul ar i t i es such as sl i ght def ect s, cont ami nat i on sour ces, i naccessi bl e pl aces, and sour ces of qual i t y def ect s

• El i mi nat e unnecessar y and sel dom- used i t ems, and si mpl i f y equi pment

42

Hardware Goals (Keys for workplace audits)

• Pr event accel er at ed det er i or at i on by el i mi nat i ng t he envi r onment al st r ess of dust and di r t

• Rai se t he qual i t y of checki ng and r epai r wor k and r educe checki ng and r epai r t i mes by el i mi nat i ng dust and di r t

• Est abl i sh basi c equi pment condi t i ons• Expose and deal wi t h hi dden def ect s


43

Human Goals (Keys for SGA audits)

• Get oper at or s i n t ouch wi t h t hei r equi pment t o make t hem mor e f ami l i ar wi t h i t , devel op a sense of owner shi p and concer n, and st i mul at e t hei r cur i osi t y about i t

• Enabl e gr oup l eader s t o l ear n about l eader shi p by i mpl ement i ng t hi s st ep i n smal l gr oups

• Enabl e peopl e t o r ecogni ze sl i ght def ect s and ot her i r r egul ar i t i es


44

Roles of Managers and Staff (fostering motivation, ability, and opportunity)

• Expl ai n t he r el at i onshi p bet ween cont ami nat i on and accel er at ed det er i or at i on ( mai nt ai nabi l i t y) – t hat i s, expl ai n t he meani ng of “opt i mal condi t i ons”

• Poi nt out t he most i mpor t ant par t s t o keep cl ean and expl ai n t he i mpor t ance of basi c equi pment condi t i ons ( cl eani ng, l ubr i cat i ng, and t i ght eni ng) . Teach usi ng nut s, bol t s and l ubr i cat i on manual s

• Expl ai n t he s i gni f i cance of “i nspect i on t hr ough cl eani ng”




STEP 1

Step 1Step 2

Step 3

Step 4

Step 5

Step 6

Step 7

Perform initial cleaning

Address contamination sources and inaccessible places

Establish cleaning and checking standards

Conduct general equipment inspection

Perform general process inspection

Systematize autonomous maintenance

Practice full self-management

Step 0

Preliminary activities

47

The Basis of Autonomous Maintenance is Initial Cleaning.

Start with cleaning by yourself with waste.

1. Inspect even the inside of the machine.

2. Trace the source of dust and dirt.

Cleaning is inspection.

48

The I mpor t ance of Cl eani ng

Why cl ean ?• Dust damages machi nes.

Det ai l ed cl eani ng t o r emove al l cont ami nat i on ensur es t hat al l par t s of equi pment i s t ouched. Onl y i n t hi s way can we f i nd hi dden def ect s.

49

The I mpor t ance of Cl eani ng

Fai l ur e Di r t and f or ei gn mat t er penet r at es r ot at i ng par t s, s l i di ng par t s, pneumat i c and hydr aul i c syst em, el ect r i cal syst em, and sensor s, et c. , causi ng l oss of pr eci s i on, mal f unct i on, and f ai l ur e as a r esul t of wear , bl ockage, f r i ct i onal r esi st ance, el ect r i cal f aul t s, et c.

Qual i t y Def ect s

Qual i t y def ect s ar e caused ei t her di r ect l y by cont ami nat i on of t he pr oduct wi t h f or ei gn mat t er or i ndi r ect l y as a r esul t of equi pment mal f unct i on.

Accel er at ed Det er i or at i on

Accumul at ed dust and gr i me make i t di f f i cul t t o f i nd and r ect i f y cr acks, excessi ve pl ay, i nsuf f i c i ent l ubr i cat i on, and ot her di sor der s, r esul t i ng i n accel er at ed det er i or at i on.

Speed Losses Dust and di r t i ncr ease wear and f r i ct i onal r esi st ance, causi ng speed l osses such as i dl i ng and under per f or mance.

Harmful Effects of Inadequate Cleaning

50

Key poi nt s f or cl eani ng

• Cl ean equi pment r egul ar l y as par t of dai l y wor k.

• Cl ean deepl y ― r emove al l t he l ayer s of gr i me and scal e bui l t up over many year s

• Open pr evi ousl y i gnor ed cover s, guar ds, and so on, t o expose and r emove ever y speck of di r t f r om ever y cor ner and cr evi ce.

• Cl ean at t achment s and accessor i es as wel l as mai n uni t s , e. g. , conveyi ng equi pment , cont r ol boxes, and l ubr i cant t anks ( bot h i ns i de and out ) .

• Do not gi ve up when a par t get s di r t y agai n soon af t er c l eani ng. I nst ead, car ef ul l y not e how l ong i t t akes t he par t t o become cont ami nat ed agai n, wher e t he cont ami nat i on i s comi ng f r om, and how sever e i t i s .

51

On t he f l oor

( 1) Cl eani ng of t he f l oor

52

　　 Cl eani ng of t he f l oor i s qui t e easy to tackle with 　 and is very efficient in creating clean atmosphere 　 within the shop.

　　 It contributes a great deal in giving workers 　comfort 　 ability.

　　 This is the topic that is to be considered right 　after eliminating unnecessary items.

St ar t i ng f r om cl eani ng of t he f l oor

53

Mai n st eps :

1. Fi r st , c l ean by br ooms

2. Dr aw sect i on l i nes

3. Tr y t o shut out dust and st ai n

4. Ver y f i ne cl eani ng

54

1. Fi r st , c l ean by br ooms

* Sect i on chi ef s or l eader s t hemsel ves must t ake br ooms and t ake t he l ead i n c l eani ng

2. Dr aw sect i on l i nes

* Sect i on l i nes of passages

* I ndi cat i on on t he f l oor of 　car r i er s, t he st or i ng pl ace 　of i n- pr ocess 　 i nvent or y, 　 and t he sect i ons wher e i t 　 i s pr ohi bi t ed t o put t hi ngs.

* Pi ct ur es on t he f l oor t o show　 t he f i xed posi t i ons of smal l　 f aci l i t i es such as gar bage can, 　 ash t r ays or f i r e ext i ngui sher s.

55

* Oi l l eakage f r om machi nes　 By cl eani ng i nspect i on of machi nes,

f i nd t he pl ace 　 wher e oi l i s l eaki ng and i mpr ove i t .

* Wat er l eakage f r om t anks or pi pes Regi st er t hem and i mpr ove one by

one.

* Mi st , dust or chi ps

　　 I mpr ovement of t he cr evi ce bet ween t he cover and 　 t he body, or t he pr oper i nst al l at i on of t he cover

　　 I nspect i on of t he suct i on syst em ( especi al l y l eakage or bl ocki ng) .

3. I mpr ovement t o shut out t he sour ce of dust 　 and st ai n

56

Poi nt s I nvol ved: Expect ed Benef i t s :

• El i mi nat i ng t he pr obl em of c l eani ng har d- t o- r each pl aces

• Rat i onal i zes cl eani ng oper at i ons t o st r eaml i ne wor kpl ace

Manuf act ur i ng of t en pr oduces di r t and shavi ngs t hat must be cl eaned

har d t o c l eaneasy t o c l ean

cor ds and pi pescover

Wr ap and suspend cor ds and pi pes

Thi s c l ear s t he f l oor , maki ng i t easy t o c l ean

Cl osed pal l et ends make cl eanup easi er

57

Poi nt s I nvol ved: Expect ed Benef i t s :•Oi l pans ar e not necessar y unl ess t her e ar e oi l l eaks•Lear n t o i dent i f y t he causes of oi l l eaks

•5S can be mor e ef f ect i ve•A compl et el y ef f i c i ent wor kpl ace can be achi eved

1. Compl et el y mop up t he oi l t hat has l eaked

2. Obser ve f or a whi l e, unt i l oi l st ai ns appear

3. Tr ace t hese t o t hei r sour ce4. Typi cal causes: l oose bol t s and

nut s, packi ng def ect s5. Make met hodi cal i nspect i ons,

mai nt enance, and r epai r t o keep machi ne l eak- f r ee

Using an oil pan has kept the

surrounding area clean, but the

cause of oil leak itself has not been

solved

St op t he oi l l eak and el i mi nat e t he oi l pan!

To do t hi s:

58

* Adher ence of past e- l i ke t hi ng causes scat t er i ng or 　 dr i ppi ng.

　　 I mpr ovement of t he par t t hat causes scat t er i ng or 　 dr i ppi ng.

　　 I mpr ovement of t he i nj ect i on met hod and r et r i eval 　 met hod.

　　 Adopt i on of r emoval sheet s.

* Car r yi ng i n and out of dust or st ai n　　 A dust r emovi ng mat t r ess shoul d be

pl aced at 　 t he ent r ance. I t shoul d not be necessar y f or a 　 wor ker t o st op on t he mat t r ess but j ust t o pass on 　 i t so t hat dust must be r emoved aut omat i cal l y.

59

* Cl eani ng of oi l t hat i s st ai ned on t he f l oor

　　 - - Cl eanser must be used and t he f l oor must be 　

　　　　 c l eaned r epeat edl y.* Wax or pai nt i s t o be appl i ed t o

pr event dust f r om　 concr et e.　 At pr eci s i on needed f act or i es wher e

dust or st ai n i s 　　 l east wel come, t he f l oor must be cl eaned

　 t o t he ext ent t hat i t can be t ouched　 wi t h c l ean hands.　 Such cl eani ng shoul d be ext ended 　　 t o t he wal l or ot her par t s of 　　 t he bui l di ng.

4. Fi ne l evel of cl eani ng

60

　 Dust and l umps i n pai nt i ng

　 Noi se of pr eci s i on r ot at i ng par t s whi ch r e-

qui r e good sound char act er i st i cs

　 St r eaks on t he met al of t he r ot at i ng 　machi ne

　 Cr unches of oi l pr essur ed machi nes

* Typi cal exampl es:

Thi s must be car r i ed out by t he cooper at i on of t he l i ne peopl e and t he t echni cal st af f

( 2) I mpr ovi ng chr oni c qual i t y def ect whi ch i s caused di r ect l y by dust or st ai n

61

　 Dust on opt i cal i nst r ument s

　 For ei gn body on chemi cal or medi cal 　

appl i ances

　 Smal l i r r egul ar unevenness of a

pr eci s i on 　 pl at e maki ng pl ant

　 I r on cont ami nat i on at a pot t er y pl ant

　 Dust or noi se of pr eci se

el ect r omagnet i c 　 pr oduct s

　 St ai n at a dye- pr ocess pl an 　

62

• Mai n poi nt s t o be at t ended:

　　 Tr y t o f i nd out t he t r ue causes f or dust or 　 st ai n - - Col l ect def ect i ve sampl es and 　 check by a mi cr oscope.

　　 Anal yze t he r out es of t he out br eak, i nvasi on, 　 and cont agi on of dust and st ai n.

　　 Thor ough cl eani ng of t he envi r onment s .

63

* Thor ough cl eani ng of t he envi r onment　　 Fl oor s, wal l s, shel ves　　 Upper sur f ace, i nsi de and l ower sur f ace of 　

machi nes or f i x t ur es　　 Cei l i ng, cor ner s of t he cei l i ng, upper par t

of pi pes　　 Upper s l i de of l amp shades　　 Upper and l ower sur f aces of shel ves 　 and oper at i onal st ands　　 I nsi de and out si de of t he cont ai ner s 　 f or t r anspor t at i on and st or age　　 Wi t h t hese measur es, chr oni c l e 　 def ect due t o dust or st ai n 　 wi l l al most be el i mi nat ed

64

* Exampl es of bl i nd poi nt s :

　　 Dust wi t hi n t he admi ssi on duct t o a c l ean r oom

　　 Cushi ons and such t o be br ought i nt o a 　cl ean r oom

　　 Mi nut e dust by ai r bl ow

　　 Oi l mi st i n t he exhaust of 　 an ai r cyl i nder or i n t he 　 l eaked ai r

　　 Di r t y washi ng l i qui d

65

* Anal ysi s of how dust comes i n and cr eat e t r oubl es

　　 Fol l owi ng i s an exampl e of sheet met al pr essi ng:

・・ I t i s easy t o r ecogni ze t hat t he r out es of i nf ect i on of dust comi ng i n and causi ng t r oubl es ar e enor mous.

66

On pal l et s f r om out si de 　 t he pl ant

Bur r by shear i ng, 　bor i ng, or pi er ci ng

Met al powder comi ng out of sander s or 　 gl i nder s i n a moul d r epai r shop

For ei gn body comi ng i n

wi t h moul ds t hat ar e kept

out si de

Wooden wast e comes out

f r om br oken wooden

sur f ace pl at e

Sawdust spr ead agai nst oi l l eakage

I n or der t o put a wi r e ar ound a moul d, a wor ker st ands on i t wi t h hi s shoes

A wi r e t ouches t he f l oor or

i s pl aced on t he f l oor

A moul d t ouches t he gr ound

when dr i ven by t he cr ane

A pr ot ect i on boar d i s

pl aced di r ect l y on t he

f l oor

Wi pe t he shoot by a wast e

f or ei gn body l i ke bur r )

Al i en subst ances st i cks t oset t i ng t ool s or measur i ngt ool s

Dust comes down f r om t he bol t hol es of t he

upper moul d

Dust comes down f r om t he ai r hol e of t he

upper moul d

Dust comes down f r om t he sl i de openi ng

A br ush f or oi l char ge t ouches t he out si de

of moul ds or f r ames

Fr ames or moul ds ar e t ouched by hands

dur i ng r ecei v i ng and del i ver y of mat er i al

For ei gn body i s br oughti n at t he t i me of oi l char ge

For ei gn body of a

l eat her gl ove i s r ubbed

agai nst t he mat er i al

For ei gn body on a gl ove i s adher ed t o

For ei gn body on a con-

veyor bel t i s adher ed t o

For ei gn body on t he

moul d sur f ace

For ei gn body on t he

mat er i al sur f ace U

ne

ve

nn

es

s

ca

us

ed

b

y

al

ie

n

su

bs

ta

nc

es

Pr ocessing

Set t i ng of t he

moul d

Tr anspor t ati on

Ma

te

ri

al

So

ur

ce

o

f

du

st

Ma

in

r

ou

te

o

f

du

st

t

ra

ns

fe

r

Mo

ul

d

67

I f I c l ean my equi pment

t hor oughl y, I won’ t over l ook

mi nor f l aws.

68

Poi nt of cl eani ng

( Gl asses of an oi l l evel er and i nst r ument )

Cannot see t he exi st ence of oi l and t he degr ee of cont ami nat i on

Cannot see t he scal e

Oi l l evel er

I nst r ument s

69


( Li mi t swi t ches) Remove at t ached dust and di r t .

70


( Lenses of a phot o cel l ) Cl ean wi t h a sof t c l ot h. .

71

Tur n cl eani ng i nt o i nspect i on.

Equi pment

St op checks ar e a chance t o di scover abnor mali t i es and det er i orat i on!

St op accel er at ed det er i or at ion!

Equi pment

El i mi nat e di r t , dust , and gr i me

72

• What can go wr ong i f t hi s par t i s di r t y?

• What happens t o t hi s col umn or pi pe when t hi s par t i s r ust y?

• How woul d t he pr oduct be af f ect ed i f t hi s wer e bl ocked?

• Thi s par t keeps on get t i ng di r t y no mat t er how of t en I c l ean i t . Wher e does t he cont ami nat i on come f r om?

When cl eani ng, answer t he f ol l owi ng sor t s of quest i ons:

Expose al l abnor mal i t i es

73

Exposi ng seven t ypes of abnor mal i t y

Abnor mal i t y Exampl es1. Mi nor Fl aws• Cont ami nat i on• Damage• Pl ay• Sl ackness• Abnor mal

phenomena

• Adhesi on

Dust , di r t , powder , oi l , gr ease, r ust , pai ntCr acki ng, cr ushi ng, def or mat i on, chi ppi ng, bendi ngShaki ng, f ai l i ng out , t i t l i ng, eccent r i c i t y, wear , di st or t i on, cor r osi onBel t s, chai nsUnusual noi se, over heat i ng, v i br at i on, st r ange smel l s, di scol or at i on, i ncor r ect pr essur e or cur r entBl ocki ng, har deni ng, accumul at i on of debr i s, peel i ng, mal f unct i on

2. Unf ul f i l l ed Basi c Condi t i ons

• Lubr i cat i on• Lubr i cant suppl y• Oi l l evel gauges• Ti ght eni ng

I nsuf f i c i ent , di r t y, uni dent i f i ed, unsui t abl e, or l eaki ng l ubr i cantDi r t y, damaged, or def or med l ubr i cant i nl et s, f aul t y l ubr i cant pi pesDi r t y, damaged, l eaki ng; no i ndi cat i on of cor r ect l evelNut s and bol t s: s l ackness, mi ssi ng, cr oss- t hr eaded, t oo l ong, cr ushed, cor r ect ed, washer unsui t abl e, wi ng nut s on backwar d

3. I naccessi bl e Pl aces• Cl eani ng • Checki ng• Lubr i cat i ng• Ti ght eni ng• Oper at i on• Adj ust ment

Machi ne const r uct i on, cover s, l ayout , f oot hol d, spaceCover s, const r uct i on, l ayout , i nst r ument posi t i on and or i ent at i on, oper at i ng- r ange di spl ayPosi t i on of l ubr i cant i nl et , const r uct i on, hei ght , f oot hol ds, l ubr i cant out l et , spaceCover s, const r uct i on, l ayout , s i ze, f oot hol ds, spaceMachi ne l ayout ; posi t i on of val ves, swi t ches, and l ever s; f oot hol dsPosi t i on of pr essur e gauges, t her momet er s, f l ow met er s, moi st ur e gauges, vacuum gauges, et c.

74

Abnor mal i t y Exampl es4. Cont ami nat i on

Sour ces• Pr oduct• Raw mat er i al s• Lubr i cant s• Gases• Li qui ds

• Scr ap• Ot her

Leaks, spi l l s , spur t s, scat t er , over f l owLeaks, spi l l s , spur t s, scat t er , over f l owLeaki ng, spi l l , and seepi ng l ubr i cat i ng oi l s, hydr aul i c f l ui ds, f uel oi l , et c.Leaki ng compr essed ai r , gases, st eam, vapor s, exhaust f umes, et c.Leaki ng, spi l t and spur t i ng col d wat er , hot wat er , hal f -f i ni shed pr oduct s, cool i ng wat er ,wast e wat er , et c.Fl ashes, cut t i ngs, packagi ng mat er i al s, and nonconf or mi ng pr oductCont ami nant s br ought i n by peopl e, f or k- l i f t t r ucks, et c. and i nf i l t r at i ng t hr ough cr acksi n bui l di ng

5. Qual i t y Def ect Sour ces

• For ei gn mat t er• Shock• Moi st ur e• Gr ai n si ze• Concent r at i on• Vi scosi t y

I ncl usi on, i nf i l t r at i on, and ent r ai nment of r ust , chi ps, wi r e scr aps, i nsect s, et c.Dr oppi ng, j ol t i ng, col l i s i on, v i br at i onToo much, t oo l i t t l e, i nf i l t r at i on, def ect i ve el i mi nat i onAbnor mal i t i es i n scr eens, cent r i f ugal separ at or s, compr essed- ai r separ at or s, et c.I nadequat e war mi ng, heat i ng, compoundi ng, mi xi ng, evapor at i on, st i r r i ng, et c.I nadequat e war mi ng, heat i ng, compoundi ng, mi xi ng, evapor at i on, st i r r i ng, et c


75

Abnor mal i t y Exampl es6. Unnecessar y and Non-

ur gent i t ems• Machi ner y• Pi pi ng equi pment• Measur i ng i nst r ument s• El ect r i cal equi pment• Ji gs and t ool s• Spar e par t s• Makeshi f t r epai r s

Pumps, f ans, compr essor s, col umns, t anks, et c.Pi pes, hoses, duct , val ves, damper s, et c.Temper at ur es, pr essur e gauges, vacuum gauges, ammet er s, et c.Wi r i ng, pi pi ng, power l ead, swi t ches, pl ugs, et c.Gener al t ool s, cut t i ng t ool s, j i gs, mol ds, di es, f r ames, et c.St andby equi pment , spar es, per manent st ocks, auxi l i ar y mat er i al s, et c.Tape, st r i ng, wi r e, met al pl at es, et c.

7. Unsaf e pl aces• Fl oor s• St eps• Li ght s• Rot at i ng machi ner y• Li f t i ng gear• Ot her

Unevenness, t r amps, pr oj ect i ons, cr acki ng, peel i ng, wear ( st eel deck pl at es)Too st eep, i r r egul ar , peel i ng ant i - s l i p cover i ng, cor r osi on, mi ssi ng handr ai l sDi m, out of posi t i on, di r t y or br oken cover s, not pr oper l y expl osi on- pr oof edDi spl aces, f al l en of f or br oken cover s, no saf et y or emer gency st op devi cesWi r es, hooks, br akes, and ot her par t s of cr anes and hoi st sSpeci al subst ance, sol vent s, t oxi c gases, i nsul at i ng mat er i al s, danger s i gns pr ot ect i ve cl ot hi ng, et c.


76

• What pr obl ems can occur i f t hi s nut or bol t i s l oose or mi ssi ng?

• What pr obl ems can occur i f t hi s oi l i s di r t y or used up?

• What pr obl ems can occur i f t hi s V- bel t or chai n i s s l ack?

Pr ovi de l ear ni ng ai ds.

Devel op one- poi nt l essons.

Tag abnor mal i t i es wher e t hey occur .

When cl eani ng, answer t he f ol l owi ng sor t s of quest i ons:

( c f . Exposi ng seven t ypes of abnor mal i t y )

( c f . Appendi x )

Expose al l abnor mal i t i es

77

Put a Label Where There is Something Wrong.

79

Tag abnor mal i t i es

One- poi nt l esson

1. Basi c knowl edge about equi pment mai nt enance

2. Act ual exampl es of br eakdowns and def ect s

3. Exampl es of equi pment i mpr ovement s

Use one- poi nt l essons

81

Oi l l eakage on t he r od of t he cyl i nder when i t moves

A good exampl e of t aggi ng

82

Check items Tagging Detagging

1. How is the oil pressure? Higher pressure. Restore to the right pressure. 　

2. 　 How is the movement of Slow the cylinder? Does not move.

4. What is the reason for the The strainer is clogged. Clean the strainer. poor operation?

6. Why was the strainer clogged? Oil was dirty. 　 Remove the oil and 　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　 clean the tank.

8. Why did the oil get dirty? Dust comes into the tank. Prevent chips and cutting oil from

dispersion.

83

３３３ Check items Tagging Detagging 6. Why did dust come in? There are holes and spaces Cover the holes and in the upper cover of the spaces.

tank. 7. How is movement? Good, but there is oil Dismantle the section

9. What is the reason for oil O ring was cut. Replace the O ring. leakage?11. What is the reason for it? There are scratches on Remove the scratch

the rod.13. Why were the scratches Dispersed chips are Take countermeasures

attached to the rod. against dispersion of produced chips.

15. How are the movement? Good. Make one-point

Leakage? None lessons.

Oil temperature? Appropriate

89

Teachi ng t eammat es

wi t h a one- poi nt

l esson

90

Why inspect ?

• Inspection traces the conditions of areas known to be prone to defect.• Inspection leads to understanding and ownership of what and how to control conditions and make the job easy.

The I mpor t ance of I nspect i on

91

When some part, if it breaks, has a risk of creating a huge damage, then it must be placed to expose it to human eyes such that its anomaly can be detected quickly enough even if such placement looks ugly. (eg. The rupture of hoses, breakdowns of cables)

92

The I mpor t ance of I nspect i on

Key Points for Inspection• Sear ch f or i nvi s i bl e as wel l as v i s i bl e def ect s, such as

l ooseness, subt l e v i br at i ons, and sl i ght over heat i ng t hat onl y t ouch can det ect .

• Sear ch car ef ul l y f or wor n pul l eys and bel t s, di r t y dr i ve chai ns, bl ocked suct i on f i l t er s, and ot her pr obl ems l i kel y t o l ead t o mal f unct i ons.

• Not e whet her equi pment i s easy t o c l ean, l ubr i cat e, i nspect , oper at e, and adj ust . I dent i f y hi ndr ances such as l ar ge, obst r uct i ve cover s, i l l - posi t i oned l ubr i cat or s, and so on.

• Ensur e t hat al l met er s oper at e cor r ect l y and ar e cl ear l y mar ked wi t h t he speci f i ed val ues.

• I nvest i gat e any l eaks of pr oduct , st eam, wat er , oi l , compr essed ai r , and so on.

• Al so hunt f or hi dden pr obl ems such as cor r osi on i nsi de i nsul at i ng mat er i al s on pi pes, col umns, and t anks, and bl ockages i nsi de chut es and duct s.

93

　 Thr ough cl eani ng, even a non-speci al i st can det ect 　 some def ect whi ch ot her wi se may not be not i ced.

　 Thi s i s cal l ed i nspect i on by cl eani ng.

( 1) I nspect i on by cl eani ng of equi pment

94

* Di r t y machi nes wi l l cause many t r oubl es.

Di r t y machi nes ar e not c l eaned 　 pr oper l y.

Because t hey ar e not c l eaned, t hey have not been i nspect ed t hor oughl y.

Because t hey ar e not i nspect ed t hor oughl y, t he

def ect s t hat wi l l cause t r oubl es ar e hi dden. ( hot bed

of wast e)Thi s i s why di r t y machi nes cr eat e a l ot of t r oubl es.

95

* Change f r om t he shop wi t h many t r oubl es t aki ng pl ace one af t er anot her i nt o t he shop of per f ect pr oduct i on - - St ar t wi t h i nspect i on by cl eani ngI f many t r oubl es t ake pl ace one af t er anot her al t hough cer t ai n count er measur es have been t aken, t r y t o i nspect t he machi ne by cl eani ng and make mi nut e i mpr ovement s st ep by st ep.

defective

rate Facility

Net

Efficiency

DefectProductive

Inspectionby cleaning

96

Tur n cl eani ng i nt o i nspect i on!

The V bel t i s wor n!

The oi l suppl y pi pe i s t ouchi ng i t !

Ther e’ s cut t i ng oi l on

t he l i mi t swi t ch

( 2) How t o car r y out i nspect i on by cl eani ng

97

* Mai n i t ems:

　　 St udy t he si t uat i on bef or ehand.　　 I nspect i on by cl eani ng.　　 Par t i c i pat i on of speci al i zed t echni ci ans.　　 I nvest i gat i on of mi nor def ect s.

98

* Si t uat i on st udy bef or ehand - - i n a meet i ng ３ of per sonnel i n char ge

　　 Dat a ar e t o be t aken on at what pl ant and what k i nd 　 of t r oubl es ar e t aki ng pl ace.

　　 The causes of t he mai n t r oubl es ar e t o be 　

　　 i nvest i gat ed.　　 Col l ect i t ems t hat ar e supposed 　　　 t o cause t he t r oubl es.

priar

investigation

99

* Mechani sms of t abl es, sl i di ng beds or ３ r ot at i ng par t s

　 Mai n check poi nt s:

1. Di f f er ence i n hei ght or dent

by dust , st ai n, cr unch or wear

of s l i di ng beds

2. Damage or wear of t he dust wi per of t he sl i di ng

beds

3. Backl ash of s l i di ng beds or r ot at i ng par t s or l oose scr ews

( 3) I nspect i on by cl eani ng : mai n check poi nt s

100

* Mai n check poi nt s common t o " movi ng" machi nes such as machi ne t ool s, pr ocessi ng machi nes or assembl y equi pment .

　 Lubr i cat i ng oi l equi pment

I nspect i on by cl eani ng i s done i n t he above or der .

Oi l suppl y mout h

Tank Pi pe

Each oi l suppl y

sect i on

101

• Mai n check poi nt s

1. Check i f i t i s di r t y ar ound t he end of t he oi l suppl y pi pe or check i f t he cover i s not br oken.

2. check t he oi l wi t hi n t he t ank ( compar ed wi t h new oi l ) .

102

　 Hydr aul i c equi pment


　 Mai n check poi nt s : 1. Check i f i t i s di r t y ar ound t he

end of t he oi l suppl y pi pe or ai r br eat her .

2. Check i f t her e i s any openi ng or space t o l et dust i nt o t ank.

3. Check t he oper at i on oi l ( compar ed wi t h new oi l ) .

Oper at i ng oi l t ank

Oper at i ng oi l pump

Cont r ol pi pes

Act uator s

103

　 Pneumat i c equi pment


Cont r ol pi pes

Act uat or s

Ai r escape

A set of 3 ai r suppl y

equi pment

104

2. Check i f t he exhaust gas si l encer i s bl ocked.

　 Mai n check poi nt s:

1. Check i f t he dr ai n wi t hi n t he ai r f i l t er i s di s- char ged or i f t he i nsi de of t he bowl i s not di r t y.

105

* El ect r i c equi pment , cont r ol equi pment

　　 Mai n check poi nt s:

　 1. Check i f t he t ape r eader sect i on of NC

　 machi nes i s not di r t y or i f l amps ar e di r t y.

　 2. Check i f f i xed scr ews l i ke l i mi t swi t ches ar e

　 not l oose or act uat or , 　 r ol l er s or pl unger s 　 ar e not damaged.

106

　 Pr oduct i on t echni ci ans - - exper t t echni ci ans on mat er i al , pr oduct s, pr ocessi ng met hods or f aci l i t i es

　 Faci l i t y t echni ci ans - - exper t t echni ci ans on pr act i cal use of f aci l i t i es, mechani sms, el ect r i c equi pment s

　 Ot her exper t t echni ci ans on measur i ng or saf et y cont r ol

( 4) Par t i ci pat i on of exper t t echni ci ans

* Not onl y oper at or s but t he f ol l owi ng exper t t echni ci ans ar e t o par t i c i pat e i n t he i nspect i on by cl eani ng.

Production technicians

Facility technicians

Other expert technicians

107

[ A r epor t by an exper t pr oduct i on t echni ci an who has sol ved a f r equent l y occur r i ng t r oubl e of an aut omat i c machi ne]

" so f ar we had t r i ed t o check a t r oubl e casual l y and 　 t her ef or e coul d not sol ve i t compl et el y. But when 　 we st ar t ed t o adopt i nspect i on by cl eani ng met hod, 　 we checked each sect i on i n det ai l , i n t he consequence we coul d br eak t hr ough and sol ve t he 　 pr obl em event ual l y. "

108

* I nspect i on by cl eani ng i s t he ent r ance t hat l eads t o 　 t he sol ut i on of chr oni c t r oubl es.

* However , i nspect i on by cl eani ng does not al ways 　 det ect al l t he def ect s t hat cause t r oubl es.

( 5) I nvest i gat i on of mi nut e def ect s besi des i nspect i on by cl eani ng

109

* Ther ef or e, on t he basi s of t he cur r ent s i t uat i on of t he 　f aci l i t i es, st udi ed t hr ough i nspect i on by cl eani ng, det ai l ed i nvest i gat i on on t he r el at i onshi p bet ween causes and t he ef f ect f or each t r oubl e must be car r i ed out i n or der t o i mpr ove t he si t uat i on.

110

I f you l et s l i ght l y abnor mal condi t i ons accumul at e, t he pr obl em wi l l get bi gger . . .

111

* Mai n poi nt s

　　 Tr oubl es on qual i t y of t he mat er i al or 　 t he pr evi ous pr ocess

　　 Ot her t r oubl es of f aci l i t i es, moul ds, or 　j i gs and t ool s

　　 Tr oubl es by oper at i on met hods, 　 pr ocessi ng condi t i ons, or handl i ng　 condi t i ons

material

Handling 　conditions

Machining　conditions

Operation

quality of previous　 process

moulds

jigs tools

facilities

112

The I mpor t ance of Lubr i cat i on

Why l ubr i cat e ?• Reduce f r i ct i on and wear• Dampen shock• Cool movi ng el ement s• Pr event cor r osi on• Seal out di r t

Poor l ubr i cat i on dest r oys machi nes !

Leaki ng oi l , poor gr easi ng, no l ubr i cat i on r egi me cr eat es

massi vel y accel er at ed wear and t ear .

113

Not e t he f ol l owi ngs:

• Oper at or s ar e not t aught t he pr i nc i pl es of l ubr i cat i on or pr obl ems t hat i mpr oper l ubr i cat i on can cause.

• Far t oo many di f f er ent t ypes of l ubr i cant ar e used and t oo many l ubr i cat i on s i t es ar e i naccessi bl e.

• Ther e i s t oo much r el i ance on mechani cal gr easer s and ot her aut omat i c l ubr i cat i ng devi ces.

• Lubr i cat i ng st andar ds ar e of t en nonexi s t ent or har d-t o- f ol l ow.

114

Lubr i cat e.

• Teach t he i mpor t ance of l ubr i cat i on usi ng one- poi nt l esson sheet s.

• Lubr i cat e i mmedi at el y whenever you f i nd t hat equi pment i s i nadequat el y l ubr i cat ed or not l ubr i cat ed at al l .

• Repl ace al l cont ami nat ed l ubr i cant s.

• Cl ean and r epai r al l di r t y or damaged l ubr i cant and l evel gauges.

• Check t o see whet her al l aut omat i c l ubr i cat i ng devi ces ar e oper at i ng cor r ect l y .

• Cl ean and l ubr i cat e al l r evol v i ng par t s, s l i di ng par t s, dr i ve chai ns, and ot her movi ng par t s.

• Cl ean and r epai r al l manual l ubr i cat i ng equi pment and l ubr i cant cont ai ner s.

115

Ti ght en.

• Secur el y t i ght en l oose nut s or bol t s .

• Repl ace mi ssi ng nut s and bol t s .

• Repl ace cr oss- t hr eaded nut s or bol t s t hat ar e t oo l ong.

• Repl ace damaged or sever el y wor n nut s and bol t s .

• Repl ace unsui t abl e wi ng nut s and washer s.

• Use l ock i ng devi ces on i mpor t ant nut s per s i s t ent l y wor k l oose.

116

Establish the Basic Equipment Conditions

Finding 113 troubles

Finding 91 problems

Finding air leakage at 10

spots

Finding 113 troubles

* Repl aci ng t he mot or pump wi t h excess el ect r i c power wi t h a mor e sui t abl e mot or pump - Savi ng of el ect r i c i t y power cost

Feeling heat

at the pipes

* Count er measur es agai nst ai r l eakage - Savi ng of $10, 000/ year of l osses

* Pr event i ng l i ne st op - Savi ng of $4, 800

117

Pr oper f ast eni ng

1. I sn’ t t her e any l ooseness?

2. Ar e t her e bol t s or nut s wher e t her e ar e hol es f or assembl y?

3. I s a bol t i nser t ed f r om t he bot t om and f ast ened by a nut at t he t op?

4. Ar e l engt hs of bol t s adequat e?

( 2 – 3 t hr eads above t he nut )

9. I sn’ t t her e l ooseness of a l ocki ng nut of an adj ust i ng bol t ?

Checki ng poi nt s of bol t s and nut s

118

Pr event i on of l ooseness

1. Ar e washer s used f or l ong hol es?

2. Ar e spr i ng washer s used t o t he nut s f or hol es whi ch ar e subj ect t o v i br at i on?

3. Ar e t her e any pr event i on devi ces f or l ooseness t o t he nut s f or hol es whi ch ar e subj ect t o sever e vi br at i on?

4. Ar e mat ch mar ks used f or cr i t i cal bol t s?

Parts assembly section

1. Leakage

2. Bad contact

3. Looseness

119

Pr event i on of l ooseness

Embedded bol t

1. Bol t l ooseness

Scr ew, bol t , et c

1. Damaged gr oove

2. Damaged wr ench

3. Damaged scr ew t hr ead

4. Losseness

5. Washer , et c

120

The l ubr i cat i on oi l management

1. Ar e 3S of l ubr i cat i on oi l st ands OK?

2. I s t her e appr opr i at e quant i t y of oi l needed t o l ubr i cat e?

3. Ar e gr ease guns and oi l j ugs wel l mai nt ai ned?

Checki ng poi nt s of l ubr i cat i on

121

Lubr i cat i on uni t s

1. I s i t possi bl e t o check oi l quant i t y t hr u t he oi l l evel gauge ( posi t i on, t he degr ee of cont ami nat i on) ?

2. Ar e t her e i ndi cat i on of t he upper and l ower l i mi t s of oi l quant i t y?

3. Ar e t her e i ndi cat i on of t he upper and l ower l i mi t s of pr essur e on t he pr essur e gauge?

4. I sn’ t t her e abnor mal noi se or over heat i ng i n pumps and mot or s?

5. I sn’ t t her e oi l l eakage?

122

Lubr i cat i on syst em

1. Do aut omat i c gr easi ng uni t s and aut omat i c oi l i ng uni t s f unct i on pr oper l y?

2. Do di st r i but i on val ves f unct i on r egul ar l y?

3. Ar en’ t t her e any dust and di r t on t he ext er nal and i nt er nal sur f aces of an oi l er ? I s t he quant i t y OK?

4. I sn’ t t her e an excess amount of gr ease or dust and di r t at gr ease ni ppl es?

123

5. Ar e t her e any damaged gr ease ni ppl es and cups?

6. I sn’ t t her e any cont ami nat i on due t o over - oi l i ng?

7. I s t her e pr oper oi l f i l m at s l i di ng sur f aces and r ol l er chai ns?Grease nipple

Grease cup

1. Defective ball

2. Deformation

3. Cap

1. Blockage

2. Defective cap

125

Rol l er chai ns

1. No wear or s l ack i n chai ns or spr ocket s?

2. Ar e pi ns and cl i ps of connect i ng l i nks pr oper l y i nst al l ed?

3. Ar e spr ocket s i nst al l ed pr oper l y?

4. I s t he t ensi on of chai ns OK?

Checki ng poi nt s of power t r ansmi ssi on

126

V bel t s

1. No scr at ches, br eakage, oi l cont ami nat i on or excessi ve wear ?

2. Ar e t ensi on of mul t i - bel t s const ant ?

3. No shi ni ng at t he bot t om of t he gr ooves of V pul l ey?

127

Bear i ng, coupl i ngs, keys

1. No pl ay at t he bear i ngs, or no abnor mal noi se?

2. Ar e axes of coupl i ngs par al l el ?

3. No pl ay at keys and key gr ooves?

128

Mot or s, br akes, speed change gear s, el ect r omagnet i c

cr ut ches

1. No over heat i ng, v i br at i on at mot or s?

2. No abnor mal noi se, v i br at i ons at speed r educt i on gear s?

3. No dust and di r t , damage on scal es or speed change handl es?

4. No abnor mal noi se, v i br at i on at el ect r o-magnet i c c l ut ches/ br akes?

129

5. No oi l cont ami nat i on, dust and di r t on t he l i ni ng pl at es?

6. No r ust on r ol l er chai ns? Ar en’ t r ol l er chai ns dr y?

7. Ar en’ t t her e di f f i cul t ar eas t o l ubr i cat e?

130

Pneumat i c uni t s

1. Ar e ai r set s of t hr ee pi eces pr oper l y i nst al l ed so t hat t hey can be checked easi l y?

2. No over heat i ng, abnor mal noi se i n el ect r o- magnet i c val ves?

3. Ar e l ooseness pr event i on met hods appl i ed t o t he scr ews of cyl i nder r ods?

4. No ai r l eakage?

Checki ng poi nt s f or pneumat i c/ hydr aul i c devi ces

132

Hydr aul i c uni t s

1. Ar e t her e i ndi cat i ons on t he oi l quant i t y gauge?

2. Ar e t her e i ndi cat i on on t he oi l t emper at ur e gauge?

I s t he t emper at ur e appr opr i at e?

3. Ar e t her e i ndi cat i ons on t he oi l pr essur e gauge?

I s t he zer o poi nt cor r ect ?

4. No abnor mal noi se, over heat i ng, v i br at i on i n pumps?

133

5. Ar e l ocki ng nut s of r el i ef val ves/ speed cont r ol l er s t i ght enough?

6. Ar e devi ces, pi pes pr oper l y i nst al l ed? No oi l l eakage?

7. No abnor mal noi se, over heat i ng i n el ect r o- magnet i c val ves?

134

Pi pi ng

1. No l ooseness i n pi pi ng and i t s c l ampi ng?

2. No f r i ct i on of hoses of hi gh pr essur e?

3. Ar e cyl i nder s i nst al l ed pr oper l y? Ar en’ t t hey i nst al l ed l oosel y?

4. Ar e l ooseness pr event i on met hods appl i ed t o t he scr ews of cyl i nder r ods?

135

Cont r ol panel s

1. Ar e t her e i ndi cat i ons f or t he l i mi t s of vol t met er s and amper emet er s? Ar e t hei r val ues appr opr i at e?

2. No def ect i ve name pl at es? No br oken l amps?

3. Ar e door s t i ght l y c l osed? Ar en’ t t her e r edundant hol es?

Checki ng poi nt s f or el ect r i ci t y

137

4. No dust and di r t i n cont r ol boxes? No unnecessar y i t ems i n t he boxes?

5. No abnor mal noi se i n r el ays?

138

El ect r i c devi ces

1. Ar e LS’ s, phot o cel l s i nst al l ed pr oper l y?

2. Ar e t he shapes of dogs of LS’ s cor r ect ?

3. No cont ami nat i on by wat er / oi l t o LS, phot o cel l s and pr oxi mi t y swi t ches?

4. No damage, pl ay i n devi ces?

5. Do emer gency st oppi ng swi t ches f unct i on pr oper l y?

139

Wi r i ng/ cabl es

1. No di sconnect i on of wi r i ng/ cabl i ng

2. Ar e ear t hed l i nes pr oper l y i nst al l ed?

3. Ar en’ t t her e excessi vel y l ong wi r es/ cabl es?

141

4. 11 St ep 24. 12 Goal s f or Cont ami nat i on Sour ces and

I naccessi bl e Pl aces4. 13 Pi npoi nt and El i mi nat e Sour ces of Leaks

and Spi l l s4. 14 Fr om Compul sor y Det er i or at i on t o

Nat ur al Det er i or at i on4. 15 Af t er I ni t i al Cl eani ng4. 16 Count er measur es agai nst t he Sour ces of

Dust and Di r t and t he Di f f i cul t Ar eas t o Access

1) Removi ng 2) Bl ocki ng 3) Gui di ng 4) Usi ng l ocal i zed cover s4. 17 Sour ces of Dust and Di r t

142

St ep 2: El i mi nat e Sour ces of Cont ami nat i on

and I naccessi bl e Pl aces

St ep 2

143

St ep 2: Addr ess cont ami nat i on sour ces and i naccessi bl e pl aces

Activities

• Reduce housekeepi ng t i me by el i mi nat i ng sour ces of dust and di r t , pr event i ng scat t er , and i mpr ovi ng par t s t hat ar e har d t o c l ean, check, l ubr i cat e, t i ght en, or mani pul at e

144


• I ncr ease i nt r i nsi c equi pment r el i abi l i t y by pr event i ng adhesi on of dust and di r t and cont r ol l i ng t hem at t hei r sour ces

• I ncr ease mai nt ai nabi l i t y by i mpr ovi ng cl eani ng, checki ng, and l ubr i cat i ng

• Cr eat e equi pment t hat does not r equi r e manual wor k


145


• Teach t he phi l osophy and pr act i ce of equi pment i mpr ovement , st ar t i ng wi t h smal l - scal e, easi l y- accompl i shed pr oj ect s

• Ger mi nat e t he seeds of i mpr ovement i deas t hr ough smal l - gr oup act i v i t i es

• Let peopl e t ast e t he t hr i l l and sat i sf act i on of successf ul i mpr ovement


146


•Encour age i mpr ovement i deas and gi ve pr act i cal hi nt s, i . e. , gi ve t echni cal gui dance and suppor t

•Teach pr obl em- sol v i ng t echni ques such as why- why anal ysi s

•Ensur e t hat ot her depar t ment s r espond pr ompt l y t o wor k r equest s

•Gi ve gui dance on t he use of mat chmar ks and vi sual cont r ol s


148

TABLE Dividing Step 2 into Sub Steps

Subst ep Maj or act i vi t y

1 Revi ew sour ce of cont ami nat i on.

2 Revi ew di f f i cul t cl eani ng ar eas.

3 Pr epar e t ent at i ve cl eani ng st andar ds.

4 Est i mat e cl eani ng i nt er val s.

5 Set cl eani ng t i me t ar get s.

6 Set i mpr ovement t ar get s.

7 Sour ce of cont ami nat i on:

7- 1 Conduct a why- why anal ysi s.

7- 2 Pl an r emedi al act i ons.

7- 3 Take r emedi al act i ons.

7- 4 Eval uat i on r esul t s of act i ons.

149

(-Continued)

8 Di f f i cul t cl eani ng ar eas:

8- 1 Conduct a why- why anal ysi s.

8- 2 Pl an r emedi al act i ons.

8- 3 Take r emedi al act i ons.

8- 4 Eval uat e r esul t of act i ons.

10 Revi se r esi dual i ssues.

11 Assess r esi dual i ssues.

12 Devel op a shor t r emedi al pr ogr am.

13 Conduct an aut onomous mai nt enance audi t .



STEP 2: Address contamination sources and inaccessible places

Step 2 1. Reduce sources of dirt

3. Improve AM work in difficult access areas

Step 2

2. Prevent the existence of material pieces spread all over the machine

Step 2 : Countermeasures against source of dust

151

Preventing Leaks and Spills

Pr event l eaki ng, spi l l i ng, spr ayi ng, or scat t er i ng

of :* pr oduct s* l ubr i cant s* hydr aul i c f l ui ds* powder s* vapor s* ot her pr ocess mat er i al s

Goal s f or Cont ami nat i on Sour ces and I naccessi bl e Pl aces

I mpr ovi ng I naccessi bi l i t yI mpr ove accessi bi l i t y of

pl aces t hat ar e har d t o :* c l ean* check

* l ubr i cat e* t i ght en* oper at e* adj ust

GOAL: Reduce t he t i me i t t akes t o cl ean, check, and l ubr i cat e

152

Pi npoi nt and El i mi nat e Sour ces of Leaks and Spi l l s

• Powder and vapor di schar ges make i t di f f i cul t t o mai nt ai n i ni t i al c l eani ng l evel s.

• Cont ami nat i on by dust and gr ease hamper s checki ng bol t s, nut s, oi l l evel gauges, and so on.

• Powder cont ami nat i on causes accel er at ed det er i or at i on, such as excessi ve wear of V- bel t s and dr i ve chai ns.

• Cont ami nat i on of l i mi t swi t ches, phot oswi t ches, and ot her sensor s causes mal f unct i on.

• Leaki ng l i qui ds and vapor s cause pr ocess uni t s, st ands, and ot her st r uct ur es t o cor r ode.

• I nf i l t r at i on of cont r ol panel s by powder s makes cont r ol unr el i abl e.

• Gener al cont ami nat i on i mpai r s t he wor ki ng envi r onment and l ower s pr oduct qual i t y.

153

Pi npoi nt and El i mi nat e Sour ces of Leaks and Spi l l s

• Accur at el y ascer t ai n t he nat ur e of t he cont ami nat i on and how and wher e i t i s gener at ed.

• Gat her quant i t at i ve dat a on t he vol ume of l eaks, spi l l s , and ot her cont ami nat i on ( t hi s hel ps oper at or s under st and t he i mpor t ance of measur ement ) .

• Encour age oper at or s t o t r ace cont ami nat i on back t o i t s or i gi nal sour ce ― bl ocks i n dust - col l ect i ng dust s and chut es, f or exampl e.

• Local i ze t he cont ami nat i on f i r st , t hen per si st ent l y r educe i t t hr ough a successi on of i mpr ovement s. Thi s pr oduces t he best r esul t s because one- shot i mpr ovement s ar e i mpossi bl e.

• Car r y out f ocused i mpr ovement s by pr oj ect t eams t hat i ncl ude manager s and t echni cal st af f . The pr oj ect t eam appr oach i s essent i al when deal i ng wi t h maj or cont ami nat i on sour ces t hat oper at or s cannot handl e t hr ough aut onomous mai nt enance.

• Consi der usi ng novel t echni ques and mat er i al s f or seal s, j oi nt s, pr ot ect i ve devi ces, and so on.

Fol l owi ng ar e key poi nt s f or r emedyi ng cont ami nat i on r esour ces:

154

From Compulsory Deterioration to Natural Deterioration

1. Relationship between problems and compulsory deterioration

* Natural deterioration: Things deteriorate naturally as they are used properly.* Compulsory deterioration Things are deteriorated by outside force.The two sources of compulsory deterioration:* Equipment ... no prevention of causes of dust, dirt and sca

ttering.* Operator ... unmaintained basic conditions such as clean

ing, lubricating and bolting, human errors.

155

"Compulsory deterioration" caused by operator's improper act.

Take countermeasures at the source of problems by localization and change "compulsory deterioration" into "natural deterioration."

156

1. Count er measur es t o sour ces of dust and di r t

The met hods not t o gener at e t hem３

( 1) Not t o gener at e t hem

( 2) Reduce t hei r quant i t y

2. Count er measur es t o di f f i cul t ar eas t o access

The met hods t o col l ect and r emove t hem３

( 1) How t o col l ect t hem

( 2) How t o r emove t hem

Af t er I ni t i al Cl eani ng

157

I ni t i al c l eani ng

The sources of dust and dirt

The di f f i cul t ar eas To access

• El i mi nat i on of t he sour ces of l eakage

• Local i zed dust col l ect or s

• I nst al l at i on of t he cover s of pr ot ect i ng scat t er i ng

• Bet t er means f or c l eani ng and l ubr i cat i on

• Cent r al i zed l ubr i cat i on

• I nst al l at i on of i nspect i on wi ndows

• Neat l y ar r anged wi r i ng and pi pi ng

I mpr ovement

Conf i r mat i on of ef f ect s

Count er measur es t o Sour ces of Dust and t he Di f f i cul t Ar eas t o Access

158

Trouble due to foreign matter, dust, dirt, etc.

The floor must be cleaned until no dirt can be detected on stroking with the palm of the hand or a white glove

water-soaked mat

water tray

Dust and dirt brought in by trolleys, movement of pallets, packing materials and machines, movement of people, ingress of outside airScattering of sawdust, paper fibers, etc.

Floor dust and dirt raised by cleaning, movement of people, and placing wire slings, containers, etc. on floor

Contamination brought in on the work itself

Contamination created by processing the work

Dust falling from beams, crane hoists, vent pipes, etc.

Splattering and dropping of oil, water, dirt, etc.

sweat from hands, etc.

factory

Fig.

Sour ces of Dust and Di r t

159

Countermeasures:

1. Wax or paint floors2. Keep ceiling beams and cranes clean3. Provide wet mats at entrances4. Fit wheels with brushes or rags5. Ensure that interior of workshop is not at

negative pressure6. Do not install large-capacity ventilation

equipment unless absolutely necessary

attach brush or rag

grime collectorgrime collector

brush

Fig. (Cont’d) Measures against sources of contamination in precision machine shops

160

Count er measur es agai nst dust by i nt r oduci ng cl eani ng br ushes

Cl eani ng br ushes

1. Removi ng

161

Bel t conveyorPr obl em : Bel t conveyor s get di r t y.

Sol ut i on : I nst al l a bel t c l eaner t o mai nt ai n c l eanness of t he bel t conveyor .

One poi nt l esson : I nst al l t he cl eaner i nsi de t he dust pr ot ect i on cover .

Conveyor bel t

Bel t c l eaner

Sponge r ubber

Spr i ng

Sponge r ubber hol der

Mat er i al : har d sponge r ubber ( neopr ene)

162

Count er measur e agai nst dust usi ng br ushes on bot h si des,

Li f t i ng dust i n t he ai r and sucki ng i t by vacuum

Paper dust el i mi nat or by usi ng br ushes f r om bot h si des

163

Count er measur es agai nst dust and easy r emoval of

col l ect ed dust

1. St eel cover acr yl i c cover

2. Br ush t o t ake of f dust

3. Local i zed r emovabl e cover t o col l ect dust

164

Br ush

Expl oi t oper at i onal movement f or cl eani ng at t he same t i me

Br ush

165

2) Bl ocki ng

166

An openi ng f or a bear i ng by cut t i ng t he dust pr ot ect i on coverPr obl em : Dust and di r t wi l l come out f r om t he openi ng.

Sol ut i on : Cover by magnet sheet .

Cover by st eel pl at e and cal k i ng mat er i al .

One poi nt l esson : Use magnet i c sheet or st eel pl at e wi t h cal k i ng mat er i al so t hat t he bear i ng can easi l y be di smant l ed. An openi ng by cut t i ng t he dust

pr ot ect i on cover

Cover t he openi ng by magnet i c sheet .

Cover t he openi ng by st eel pl at e and cal k i ng mat er i al .

167

Pi t f or measur i ng i nst r umentPr obl em : Dust and di r t ar e accumul at ed i n a pi t .

Sol ut i on : I nst al l r ubber sheet .

One poi nt l esson : Use ver y t hi n, l i ght and f l exi bl e r ubber sheet or v i nyl sheet f or dur abi l i t y. .

Rubber sheet

Measur i ng t abl e

168

Tappi ng machi nePr obl em : Powder dr ops ont o t he pi t at t he t i me of f eedi ng powder i nt o a moul d. Sol ut i on : Pr event powder f r om f al l i ng t o t he pi t by pr ovi di ng t he moul d wi t h bel l ows.

Moul d

Bel l ows

Tappi ng machi ne

169

Bel t conveyorPr obl em : Ther e i s powder l eakage and dust gener at i on at t he di schar gi ng sect i on of a bel t conveyor .

Sol ut i on : I nst al l a dust pr ot ect i on cover .

One poi nt l esson : The cover shoul d be abl e t o be di smant l ed easi l y. For a smal l openi ng, use magnet i c sheet or pl ast i c sheet wi t h s i l i con cal k i ng mat er i al .

Dust pr ot ect i on cover

3) Gui di ng

170

Scat t er i ng pr ot ect i on cover

Chi p t r ay

Rubbi sh dr awer

171

Bel t conveyor

Pr obl em : Ther e i s over f l ow of r aw mat er i al and powder l eakage t akes pl ace.

Sol ut i on : I nst al l a v i br at or t o r emove mat er i al .

One poi nt l esson : I n case of a smal l bel t conveyor , use an el ect r o- magnet i c f eed.

Di schar ge chut e

172

No scattering any more !

It is impossible to clean, lubricate and inspect.

4) Usi ng l ocal i zed cover s

173

Use of localized cover

1. Is the supply of coolant concentrated on the cutting point correctly?

2. Grasp the direction, angle, quantity and speed of scattering.

3. Aren'tthere any problems of operationability and safety?

174

Poi nt s I nvol ved:

Expect ed Benef i t s :• Pr event i ng scat t er i ng of

dust , et c. , at t he sour ce of t he pr obl em

• I mpr oves envi r onment• I mpr oves qual i t y• I ncr eases pr oduct i v i t y

I s t he cover f unct i oni ng as a dust r emover ? Reconst r uct ed so t hat dust i s sucked i n

dust

175

Smal l Local i zed Cover , Bi g Joy

Let's start by making a local cover "by hand."

176

Ki nds of Local i zat i on Cover s

"Covering board type" low cost, easy to make.

・ Change the material into plastic, rubber or

steel plates."Box type"not much cost, big effects.・

177

Af t er I mpr ovement

Pr esent Condi t i on

hi gh- t emper at ur e chamber

heat f l ap

door

di f f usi on

Obser vat i on:

Ent r ance t o hi gh- t emper at ur e el ect r i c f ur nace has a heat f l ap t o pr eser ve t he t emper at ur e wi t hi n t he chamber . As pr oduct s ent er t he el ect r i c f ur nace, however , t hey br ush agai nst t he f l ap and an excessi ve amount of heat st i l l escapes.

Af t er I mpr ovement s:

Di f f usi on out si de t he f ur nace was r educed by i nst al l i ng a ser i es of 3 f l aps wi t h di f f er ent l engt hs.

178

The number of brea

kdowns Stopping

Defectives

Localization

181

Exampl e ( 1) : A l ocal i zed cover f or di sper si on of cut t i ng chi ps

Dust col l ect i ng i nl etCut t i ng

bl ade

Bobbi n

Bobbi n chuck

Dust col l ect i ng i nl et

Cut t i ng bl ade

Bobbi n

Chi ps



Dust col l ect i ng box

Vacuum pump

( 1) Col l ect i ng met hod of chi ps

Di sper si on of

cut t i ng chi ps

Pr obl emsTher e i s a bi g space bet ween

t he cut t i ng bl ade and t he

cover

Power of absor pt i on i s

di sper sed

Chi ps ar e scat t er ed

182

( 2) Sur vey on scat t er i ng when t he dust col l ect i on cover i s not i nst al l ed ( shot by a hi gh- speed v i deo camer a) .

area Aarea A

area Barea B

Scat t er i ng ci r cl e gr aph

• Scat t er i ng of chi ps f r om sect i on 70%⇒• Scat t er i ng of chi ps f r om t he r ot at i ng cut t i ng bl ade ⇒30%

183

•　 I t t akes 20 mi n/ day t o c l ean t he scat t er ed chi ps j ust ar ound t he cut t i ng sect i on, and 86 mi n/ day t o c l ean t he t ot al ar ea.• Thi s c l eani ng t i me i s t he bi ggest l oss i t em, and 54. 8% of al l non- val ue added l oss t i me.• The t ot al l ost t i me due t o c l eani ng i s 1720 mi n/ mont h.

184

( 3) Sur vey on scat t er i ng and c l eani ng t i me i n case of t he convent i onal dust col l ect i on cover ( shot by a hi gh speed v i deo camer a)


Wi t hi n t he dust col l ect i ng i nl et

Wi t hi n t he dust col l ect i ng i nl et

Bobbi n chuck

Bobbi nCut t i ng chi ps

ar ea A

ar ea B

ar ea A

ar ea B


• 25% of t he act ual chi ps scat t er ed i s col l ect ed.• Chi ps comi ng out f r om t he cut t i ng sect i on 40% ( ar ea ⇒A)• Di sper sed chi ps by cent r i f ugal f or ce 30% ( ar ea B)⇒• Ti me r equi r ed f or c l eani ng ar ound t he cut t i ng sect i on 20 mi n/ day

185

(4) 1st improvement (improvement of the bobbin chuck and the change of the shape of the cover)

Shape of t he col l ect i ng i nl et ( f r ont )

Shape of t he col l ect i ng i nl et

Cut t i ng chi ps Cut t i ng

bl ade

New bobbi n chuck

New col l ect i ng cover

186

I mpr ovement poi nt

1. Space bet ween t he cut t i ng bl ade and t he cover →　minimum

2. Space at t he bobbi n cut t i ng sect i on →　 minimum (improvement of the chuck)

• Suct i on l oss• Less cut t i ng chi ps bei ng scat t er ed out of t he space.

Lef t over pr obl ems

1. Chi ps st i l l come out of t he space bet ween t he cut t i ng bl ade and t he cover .

2. Chi ps whi ch st i ck t o t he bl ade wi l l scat t er by t he cent r i f ugal f or ce.

187

( 5) Conf i r mat i on of t he ef f ect by t he 1st i mpr ovement

I nsi de t he col l ect i ng chi ps i nl et

I nsi de t he col l ect i ng chi ps i nl et

Cut t i ng chi ps

Cut t i ng bl ade

ar ea B

ar ea B


• I t i s possi bl e t o col l ect al l t he chi ps whi ch scat t er out of t he cut t i ng sect i on.• 20% of t he chi ps st i l l scat t er out by cent r i f ugal f or ce.

• Ti me r equi r ed f or c l eani ng ar ound t he cut t i ng sect i on

: 3 mi n/ day

188

( 6) 2nd i mpr ovement ( I mpr ovement of t he shape of t he cover and set t i ng t he saucer )

Shape of t he chi ps col l ect i ng i nl et ( f r ont )

New chi ps col l ect i ng cover

Cut t i ng chi ps

Shape of t he i nl et

Chi ps col l ect i ng i nl et

Saucer

I mpr ovement poi nt

1. Space bet ween t he cut t i ng bl ade and t he chi ps col l ect i ng cover →　 No space

2. Scat t er ed chi ps →　collected by saucer

• Concent r at i on of sucki ng f or ce• Pr event i on of chi ps scat t er i ng

189

( 7) Conf i r mat i on of t he ef f ect by 2nd i mpr ovement

Saucer

Cut t i ng chi ps

I nsi de t he chi ps col l ect i ng i nl et

Scat t er i ng ci r cl e gr aphI nsi de

t he saucer

Chi ps col l ect i ng cover

• I t has become possi bl e t o col l ect chi ps whi ch scat t er out of t he cut t i ng 　

　 section by centrifugal force.• The chips which have not been collected are gathered in a saucer.• Now it is scarcely necessary to clean the cutting section.

190

Reduct i on of t he amount ( and c l eani ng t i me) of cut t i ng chi ps at t he bobbi n cut t i ng sect i on by t he i mpr ovement of chi p col l ect i ng i nl et ( shape, i nduct i on ar ea) .

Shape of t he chi p col l ecti ng i nl et of t he cover

Chi p col l ecti ng i nl et ( i nducti on ar ea)

BM 1st i mpr ovement

2nd i mpr ovement

Amount of cut t i ng chi ps ar ound t he cut t i ng sect i onCl eani ng t i me ar ound t he cut t i ng sect i on

20 mi n. / day

3 mi n. / day

0 mi n. / day

20 ３ 6 ３5. 8 ３

0 ３

20. 9 cm2. 0 cm 0. 8 cm2

22

191

Name Funct i on Not e

1 Saf et y

mechani sm

Equi pment → per son

A per son i s pr ot ect ed agai nst t he i nj ur y. ( I f t he equi pment i s opened , an equi pment power suppl y and ai r suppl y wi l l st op aut omat i cal l y. )

heat Heat → per son I t pr ot ect s a per son f r om heat and bur ni ng.

ant i -expl osi o

n

Expl osi on →per son

A per son i s pr ot ect ed agai nst t he expl osi on.

2 Soundpr oof i ng Noi se → per son

I t shut s of f t he noi se of t he equi pment .

3 Exhaust Equi pment → envi r onment

I t l eads gas, st eam, col d ai r , war m ai r , and so on t o t he duct . ( hood)

4 Pr event i on of spl ash

Dust → equi pment

Di r t , dust , and so on ar e conf i ned. ( a l ocal cover )

5 Pr event i on of dr op

Equi pment → f or ei gn subst ance

Dr op of a par t and a pr oduct t o t he i nsi de of t he equi pment and t he f l oor i s pr event ed.

6 Pr oduct pr ot ect i on

Envi r onment → pr oduct

Pr oduct s ar e pr ot ect ed agai nst di r t , dust , heat and so on.

The f unct i ons of l ocal i zed cover s

192

Name Funct i on Not e

7 Pr ot ect i on of equi pment

Envi r onment → equi pment

Equi pment ar e pr ot ect ed agai nst di r t , dust and so on ( t he dust – pr oof , t he shi el d)

8 Pr event i on of i mpr oper oper at i on

Per son → equi pment

I f a cover i sn’t opened, a swi t ch can’t be oper at ed.

9 The oper at i on gui dance

Oper at i on i mpr ovement

Oper at i ng pr ocedur e i s shown i n t he t r anspar ency cover .( t he i l l ust r at i on, t he number s)

10

The i nspect i on, di agnosi s f unct i on

Mai nt ai nabil i t y i mpr ovement

A st andar d f or i nspect i on and so on i s i ndi cat ed t o t he t r anspar ency cover c l ear l y. ( bel t l ooseness l i mi t )

11

Appear ance Appear ance Unt i di ness of wi r i ng and pi pi ng i nsi de t he equi pment i s hi dden.

12

Desi gn Appear ance Just f or good appear ance cover ( t hi s must be r educed as much as possi bl e)

( -cont i nued)

193

dust

dirt Local-ization

I can clear in a short time.

It is easy to lubricate and to inspect.

It is easy to do setup.

Prevention of scattering is important!

Breakdowns and defec-tives have been reduced ! !

Further challenge !

Local i zat i on wi l l br i ng about …

194

I nspect i on t i me r educt i on

Measur e cl ocks i dent i f yi ng wi t h gr een and r ed zone

Show f l ows di r ect i on and t ype of f l ui de i nsi de t he t ubes

Wi ndows t o f aci l i t at e i nspect i on

195

Breakdowns due to lack of basic conditions

5,07

7,53

5,07 5,2

3,58

4,99

2,32,78

1,12

0 0 0 0 0 0 00

5

10

15

20

25

JULY

SE

PT

EM

BE

R

OC

TO

BE

R

NO

VE

MB

ER

DE

CE

MB

ER

JAN

UA

RY

FE

BR

UA

RY

WE

EK

10

WE

EK

11

WE

EK

12

WE

EK

13

WE

EK

14

WE

EK

15

WE

EK

16

WE

EK

17

WE

EK

18

012345678

Breakdowns due to lack of basic condit ions Breakdowns t ime (hours)

MODEL AREA: No. of breakdowns / Machine stoppage hours

STEP 1

Br eakdowns due t o l ack of basi c condi t i ons moni t or

STEP 2

196

B/ C Anal ysi s

B/C = 2,82

INSPECTION TIME REDUCTION

2,12

2,152,25

2,35

2,62,8

33

0

0,5

1

1,5

2

2,5

3

3,5

4

W 10 W 11 W 12 W 13 W 14 W 15 W 16 W17 W18

Ave

rag

e ti

me

B/C = 33,67

Breakdowns due to lack of basic conditions

5,07

7,53

5,07 5,2

3,58

4,99

2,32,78

1,12

0 0 0 0 0 0 00

5

10

15

20

25

JULY

SE

PT

EM

BE

R

OC

TO

BE

R

NO

VE

MB

ER

DE

CE

MB

ER

JAN

UA

RY

FE

BR

UA

RY

WE

EK

10

WE

EK

11

WE

EK

12

WE

EK

13

WE

EK

14

WE

EK

15

WE

EK

16

WE

EK

17

WE

EK

18

012345678

Breakdowns due to lack of basic condit ions Breakdowns t ime (hours)

197

AM standard

Team Working Method

Tag Classification and analysis

Activity to transfer from PM to AM?

U.O. P.E., G.I. P.E., Maintenance leader, Team AM Leader

Training to AM operators

Autonomous maintenance standard creation

AM Standard Scheduling

AM Standard check

Activity Responsible

yes

no

Maintenance operator, AM operators

U.O. P.E., G.I. P.E.,Maintenance operator, Team AM Leader , AM operators

U.O. P.E., Leader Team AM

U.O. P.E., Leader Team AM

198

AM Standard Samples

Color Code to identify different type of activity:

Inspection

Cleaning

Each activity explained with photo and

instructions

199

4.18 Step 34.19 Establish Cleaning, Lubricating and Inspection Standard

s4.20 How to Reduce Time Required for Cleaning4.21 How to Reduce Time Required for Inspection4.22 How to Reduce Time Required for Lubricating4.23 AM Calendar4.24 How to Make Check Lists4.25 Introduce Extensive Visual Controls4.26 Step 44.27 Step 54.28 Step 64,29 Step 7

200

St ep 3: Est abl i sh Cl eani ng, Lubr i cat i ng and

I nspect i on St andar ds

Step 3

201

Step 3: Establish Cleaning, Lubricating and Inspection Standards

Activities

• For mul at e wor k st andar ds t hat hel p mai nt ai n c l eani ng, l ubr i cat i ng, and t i ght eni ng l evel s wi t hi n mi ni mal t i me and ef f or t

• I mpr ove t he ef f i c i ency of checki ng wor k i nt r oduci ng vi sual cont r ol s

202


• Sust ai n t he t hr ee basi c condi t i ons f or mai nt ai ni ng equi pment and pr event i ng det er i or at i on ( c l eani ng, l ubr i cat i ng, and t i ght eni ng)

• Per f or m accur at e checki ng by means of v i sual cont r ol s such as equi pment namepl at es and cor r ect oper at i ng r ange di spl ays on gauges

St ep 3: Est abl i sh Cl eani ng, Lubr i cat i ng and I nspect i on St andar ds

203


• Ensur e t hat oper at or s obey st andar ds and l ear n t hei r i mpor t ance ( i . e. , under st and what wor kpl ace management i s) by havi ng t hem set t hei r own

• Let peopl e l ear n t he i mpor t ance of t eamwor k by maki ng t hem awar e of t hei r i ndi v i dual r ol es


204


• Gi ve hi nt s on wr i t i ng and pr esent i ng cl eani ng and i nspect i on st andar ds

• Gi ve t echni cal assi st ance i n pr epar i ng l ubr i cat i ng st andar ds

• Descr i be how vi sual cont r ol s can si mpl i f y checki ng, and gi ve pr act i cal advi ce


205

TABLE Driving Step 3 into Substeps

1. Conduct educat i on f or l ubr i cat i on.

2. I dent i f y l ubr i cat i on poi nt s and sur f aces.

3. Al l ocat e r out i ne l ubr i cat i ng t asks.

4. Set t ent at i ve l ubr i cat i ng t asks.

5. Est i mat e l ubr i cat i ng i nt er val s.


206

TABLE Driving Step 3 into Substeps (Cont’d)

6. Set l ubr i cat i ng t i me t ar get s.

7. Set i mpr ovement t ar get s.

8. Sour ces of cont ami nat i on:


1. I dent i f y l ubr i cat i on r el at ed sour ces.

2. Pl an r emedi al act i ons.3. Take r emedi al act i ons.4. Eval uat e r esul t s of act i ons.

207


9. Equi pment def ect s:


1. I dent i f y equi pment def ect s.2. Rest or e equi pment def ect s.

10. Di f f i cul t cl eani ng ar eas:1. Conduct a why- why anal ys i s .2. Pl an r emedi al act i ons.3. Take r emedi al act i ons.4. Eval uat e r esul t s of act i ons.

11. Revi ew l ubr i cat i ng st andar ds

208


12. Compar e wi t h l ubr i cat i ng st andar ds set by f ul l - t i me mai nt enance.

13. Set cl eani ng and l ubr i cat i ng st andar ds.

14. Devel op a shor t r emedi al pr ogr am.

15. Conduct an aut onomous mai nt enance audi t .




Step 3

1. Establish Cleaning, Lubricating and Inspection Standards.

2. Describe how visual controls can simplify checking, and give practical advice.

3. Give technical assistance in preparing lubricating standards

4. Sustain the three basic conditions for maintaining equipment and preventing deterioration (cleaning, lubricating, and inspection).

Step 3

5. Perform accurate checking by means of visual controls

Step 3: Establish Cleaning, Lubricating and Inspection Standards

210

Establish Cleaning, Lubricating and Inspection Standards

Let the operators establishwhat standards they must maintain !

The standards made by staff are hard to maintain.Top- down st andar ds ar e never f ol l owed

211

• “ We’ ve been gi ven some st andar ds, but we don’ t r eal l y know why we have t o do t hese checks”

• “ We don’ t r eal l y under st and what we have t o check and how t o check i t . ”

• “ I f we t r y t o per f or m t he checks i n accor dance wi t h t he st andar ds, i t t akes f ar t oo l ong and we don’ t make any pr ogr ess. ”

• “ The checks ar e har d t o do because t her e ar e so many hi gh, cr amped or dar k pl aces. ”

Est abl i sh Cl eani ng, Lubr i cat i ng and I nspect i on St andar ds

212

Wi t h pr oper gui dance i n pr epar i ng st andar ds and

est abl i shi ng checkpoi nt s, peopl e wi l l have t he

mot i vat i on, abi l i t y, and oppor t uni t y t o f or mul at e

r eal i st i c st andar ds f or pr event i ng det er i or at i on

dur i ng t hei r dai l y checki ng.

Est abl i sh Cl eani ng, Lubr i cat i ng and I nspect i on St andar ds

Sel f - set s t andar ds ar e al ways obeyed.

213

I mpr ove accessi bi l i t y t o r educe wor ki ng t i me

Reduce cl eani ng t i mes.

Reduce checki ng t i mes.

I dent i f y har d- t o- l ubr i cat e pl aces.

Si mpl i f y l ubr i cat i on t asks.

Fol l ow a si mi l ar pr ocedur e f or equi pment t hat i s har d t o oper at e or adj ust .

214

Establishing Tentative Standards

Quickly Decent r al i ze Cent r al i ze ⇒ ⇒Si mpl i f i cat i on

Sur ely

El i mi nat e mi ssi ng i t ems ⇒Det er mi ne checki ng pr ocedur es and

sequences

Easi ly

Easi l y under st and at a gl ance ⇒Vi sual management and cont r ol

Avoi d uncomf or t abl e post ur e ⇒change spot s

215

How t o Reduce Ti me Requi r ed f or Cl eani ng

Limit supply of coolant and scattering in small areas.

Take countermeasures in such a way that dust and dirt will not come into the areas that are hard to clean and lubricate.

Move the important parts into the areas that remain clean.

It takes so long to clean !

216

How t o Reduce Ti me Requi r ed f or I nspect i on

Transparent acrylic board

* Number of belts

* Wear, dust and dirt

* Tension

*Vibra- tion*temperature

1. Make t he hi dden i nspect i on spot r eveal ed.

2. Pl ace t he i nspect i on spot at t he hei ght of oper at or ' s eyes.3. Make t he

hi dden par t s vi si bl e.

217

Easy to inspect

It takes too much time to inspect

strainer

strainer

218

How t o Reduce Ti me Requi r ed f or Lubr i cat i ng

Lubricate* with clean oil in right quantity* at the right charging spot* at scheduled time.

219

Breakdown

Improper oil charge

Oil is running short !

220

Too much is bad ! Oil leakage Bad

lubricationToo low is also bad !

Seizing

221

Lubrication management : “4 lubrication principles”

( 1) Check t he l ubr i cat i on oi l t ype and mi ni mi ze t he t ypes.

( 2) Set appr opr i at e l ubr i cat i on cycl es.

( 3) I mpr ove oi l char ge met hods.

( 4) Check l ubr i cat i on quant i t y and set t he r i ght quant i t y.

( of sui t abl e oi l )( at r i ght t i me)( by pr oper met hod)( wi t h r i ght quant i t y)

223

There are too many lubrication spots.

Automatic lubricating system

To each lubrication spot

224

Cent r al i zed oi l char gi ng

Two cent r al i zed l ubr i cat i on syst ems whi ch do not r equi r e t o st op t he machi ne.

Main pipe

Distribution pipe

Greasing pump

Distribution valve

Carrier guide

225

Paper

Gear Timing belt

From gear driven mechanism which requires lubrication To belt driven mechanism

which does not lubrication

Oi l Char ge- l ess

Aut omat i on f or oi l char gi ng

Oil charge by hand

Automatic lubrication

226

Ope

ratio

n si

de

fra

me

Driv

ing

side

fra

meMachine

* Bearing Greasing thru cupper pipes

Gr easi ng bear i ngs f r om out si de

227

AM Cal endar

I nspect i on i t ems.

Key poi nt s.

Met hod.

Tool s.

Ti mes.

I nt er val s.

Responsi bi l i t y.

I mpl ement per i odi c aut onomous mai nt enance, moni t or r esul t s and r evi ew – i nt r oduce aut onomous mai nt enance cal endar .

228

3. 3

229

Fi gur e : Cl eani ng and Lubr i cat i on Standar ds ( Tokai Rubber I ndust r i es)

No. 24 Expiration date: 12/81

Friction gear

Oil level

Cleaning and lubricating standards for 3-S/RL

Cleaning areasNo. Category

1

2

3

4

5

Around main frame

Main body and surroundings

Oil window

Oil supply pump and distribution valves

Inside roller pit

Cleaning check points

Lubricating areas

Letter Category

Lubricator

Friction gears

Large gearwheel

Automatic oil supply pump (for drive shaft and metal parts of rollers)

a

b

c

d

Lubrication checkpoints

230

Cleaning and lubricating standards for 3-S/RL

Plant manager:Section chief:PM engineer:Foreman:

Raw materials plant

Cleaning standards Cleaning methods

No rubber scrap adhering to frame

No scattering of rubber scrap

Oil level easy to check

No oil and dirt

Not leaking or dirty

Cleaning equipment

Remove with steel scraper; sweep up

Sweep away with broom

Wipe clean with cotton waste

Wipe clean with cotton waste

Cleaning time

15 min.

5 min.

3 min.

10 min.

30 min.

Cleaning cycle

Day Wk. Mo.

○○

○○

○

1. Tighten the automatic supply pump ring joint bolts

2. Tighten oil supply valve and check for leaks

3. Tighten the stock guide fixing bolts

Lubrication standards Lubrication methods

Lubrication tools

Lubrication time

Oil level must be between upper and lower limit (#220)

Oil level half-way up gear teeth (#32)

Gearwheel well-lubricated (open gearwheel)

Adequate oil (as measured by the oil gauge) (R50)

Pour by hand

Oil can

Drip in through oil supply port with spatula

Use oil applicator

10 min.

5 min.

3 min.

5 min.

○

○○

○

○○

○

1. Secure large gearwheel cover (no rattling)

2. Secure attachment bolts for automatic oil supply pump

3. Check 3-unit FRL and drip rate

Lubrication cycle

Day Wk. Mo.

231

Li mi t Swi t ch Oi l Pr essur e Pump

Check I t ems Check I t ems

1. Cor r ect st op posi t i on 1. Di schar ge pr essur e set cor r ect l y

2. Cor r ect l i mi t swi t ch posi t i on 2. Cor r ect amount of oi l i n t ank

3. No pl ay i n pi n 3. St r ai ner not c l ogged by debr i s

4. Rol l er on t r ack, no sl i ppage 4. Cl ean hydr aul i c oi l , no ai r bubbl es

5. No debr i s obst r uct i ng movi ng par t s

5. Cor r ect coupl i ng

6. Vol t age and cur r ent wi t hi n r at ed val ues

6. Pump and mot or axes pr oper l y cent er ed

7. Lever mot i on wi t hi n l i mi t val ues

7. No noi se, over heat i ng, or v i br at i on i n pump

8. No l i qui d or vapor on swi t ch 8. No noi se, over heat i ng, or v i br at i on i n mot or

Sampl e I nspect i on Checkl i st s

232

Check I t ems

I nspect i on Resul t s

Check I t ems

I nspect i on Resul t s

1. Cor r ect st op posi t i on

Posi t i on nor mal

OK 5. No debr i s on movi ng par t s

None OK

2. Cor r ect l i mi t swi t ch posi t i on

Posi t i on nor mal

OK 6. Vol t age and cur r ent wi t hi n r at ed val ues

Rat ed:AC 200 V 2AAct ual :198 V 1. 2A

OK

3. No pl ay i n pi n

No pl ay OK 7. Lever mot i on wi t hi n l i mi t val ues

St andar d:wi t hi n 90°Act ual :wi t hi n 60°

OK

4. Rol l er on t r ack, no sl i ppage

On t r ack OK 8. No l i qui d or vapor on swi t ch

Some cool ant on swi t ch, but i t ’ s wat er pr oof

✔

　　　　　　　　　　　　　　　　　　　 - 　　　　　　　　　　　　　　　　　　　　

233

Check Items Inspection Results Check Items Inspection Results

1. Discharge pressure set correctly?

standard:20±2 kg/cm2actual:20.5 kg/cm2

OK 5. Coupling normal?

Yes OK

2. Normal amount of oil in tank?

Within level range

OK 6. Pump and motor axes cantered?

standard ≤ 1mmoff centeractual: .08mmoff center

OK

3. Strainer free of debris?

very clogged ✔ 7. Noise, overheating, or vibration in pump?

a lot of noise, overheating, and vibration

✔

4. Hydraulic oil clean, no air bubbles?

very dirty, also cloudy

✔ 8. Noise, overheating, or vibration in motor?

No OK

　　　　　　　　　　　　　　　　　　　 - Mal f unct i oni ng Oi l Pr essur e Pump

234

How t o Make Check Li st s

* Keep the daily inspection precisely by check lists.

What and when to check.

* Check items are in the order of actual operation.

Have all the items been listed within the allowable checking time?

At the start of work During operation

Mainly lubrication inspection

Inspection by human sense

At the end of work

Mainly cleaning inspection

235

I nt r oduce Ext ensi ve Vi sual Cont r ol s

• Mar k each i t em of equi pment wi t h i t s name and number t o make ever yone awar e of i mpor t ant uni t s.

• Put mat chmar ks on nut s and bol t s t o s i mpl i f y checki ng f or s l ackness.

• I ndi cat e accept ant r anges on i nst r ument s, such as pr essur e gauges, vacuum gauges, t her momet er s, and ammet er s t o f aci l i t at e cor r ect oper at i on.

• I ndi cat e l ubr i cant l evel s, t ypes, and quant i t i es t o i mpr ove mai nt ai nabi l i t y.

• Label t he cover s of devi ces such as V- bel t s, chai ns, and coupl i ngs wi t h t hei r r ot at i on di r ect i on and speci f i cat i ons t o i mpr ove mai nt ai nabi l i t y and si mpl i f y checki ng.

• Label pi pes wi t h t hei r f l ow di r ect i on and cont ent s t o i mpr ove mai nt ai nabi l i t y, oper abi l i t y, and saf et y.

• Pr ovi de on/ of f i ndi cat i ons on val ves and swi t ched t o i mpr ove mai nt ai nabi l i t y, oper abi l i t y, and saf et y.

236

Wi r e mesh

Fi gur e. I ndi cat e Bel t Si ze on Saf et y Cover

237

gr een

or ange

r ed

shaf tbear i ng

Exampl e of bear i ng l ubr i cat i on

Vi sual cont r ol s f or oi l gauges

Col or s may be

used f or oi l

l evel cont r ol

r ed

gr een

Fl oat : l i qui d

l evel made vi s i bl e

f r om out si de

Ver i f y l ubr i cant suppl y by

checki ng f or l eaks ar ound

l ubr i cat ed par t s

No bl ocked pi pes

Use t r anspar ent

pi pi ng or c l ean

annual l y

Al ways keep gr ease

ni ppl es cl ean and f i t caps

wher e possi bl e

Lubr i cat i on i nl et di spl ay col or -

coded by t ype of

l ubr i cant

I ndi cat es number of

l ubr i cat i on poi nt s

Fi gur e. Vi sual Cont r ol s f or Lubr i cat i on

238

Cl ean gui de r ol l er sCl ean spool s

Cl ean pr i nt r ol l er s, kni ves, et c.Cl ean i nt er i or of wat er

bat hs

Cl ean di es and ni ppl es

• Keep ar ea wi t hi n 20 cm of pr oduct spot l ess• Tr y t o r educe cont ami nat i on caused by f al l i ng dust

Fi gur e. Cont act - Goods Fi ve S’ s f or Ext r usi on Li ne

239Fi gur e. Exampl e of Vi sual Cont r ol s

gauge mar k ( gr een)

check st r ainer

I ndi cat e per son r esponsi bl e on mai n val ves t o be cl osed on shut down days

I ndi cat e whet her val ve i s t o be kept open or c l osed

Use r ever si bl e t her mosensit i ve l abel t o i ndi cat e t emper at ur e

I dent i f y f l ui d usi ng JI S col or -code

f l ow di r ect i onPer son

r esponsi bl e f or

mai n val ve

Keep open

dur i ng oper at

i on

Di spl ay of r epl acement dat e on el ect r i cal par t s ( l i mi t swi t ches, r el ays, et c. )

Label showi ng r epl acement dat e

Col or - codi ng of r ecept acl es f or t r ash, r ecycl abl e wast e, et c.f l ammabl e

nonf l ammabl eExampl e:Combust i bl e mat er i al - whi t e

l et t er s on gr een backgr ound

I ncombust i bl e mat er i al - bl ack l et t er s on yel l ow backgr ound

Pi pi ngDi spl ay of easi l y mi st aken pr essi ng sequence f or but t onsI ndi cat e sequence i n bl ack

I ndi cat e sequence i n r ed

Appl i cat i on: t o di spl ay st ar t i ng sequenceTo i ndi cat e or der i n whi ch swi t ches, but t ons, et c. ar e t o be oper at ed when st ar t i ng equi pment

Appl i cat i on: t o di spl ay sequence f or st oppi ng equi pmentTo i ndi cat e or der i n whi ch swi t ches, but t ons, et c. ar e t o be oper at ed when t ur ni ng equi pment of f

Appl i cat i on: i nspect i on dat e st i ckerRecor d schedul ed i nspect i on dat e and af f i x t o par t t o be i nspect ed

３３

240

Gauge mar ks

gr een ( nor mal val ue)

r ed ( saf et y l i mi t )

I nst al l i n pumps, val ves, bear i ngs, mot or s, et c .I nser t i on of t her mocoupl es

gr een

r ed

Make i t easy t o t el l

whet her t he t her mocoupl e

i s f ul l y i nser t ed

I nt er i or

Di spl ay bel t s i ze

B- 80×3

Check f or s l i ppage usi ng t her mosensi t i ve l abel

Col or - codi ng el ect r i cal set t i ngs

Per son i n

char geMai n- t e-nance

Pr o-duc-t i on

Vol t age Dest i nati on

st i cker

Ni ght - onl y l i ght i ng: gr eenNi ght + c l oud: yel l owNi ght + r ai n: r ed

Dat e f or c l eani ng and i nspect i ng

el ement . Ar e mi cr onsi zed

f or ei gn par t i c l es bei ng t r apped? Ar e

you not onl y c l eani ng, but al so checki ng how much and what k i nd of

f or ei gn mat t er has accumul at ed?

Li ght i ng mapMain swit ch

sl ackness

l i mi t

Sl ackness l i mi t

P

I nspect i on dat es

10/ 8712/ 87

Fi gur e

241

Check f or damage and

di r t on pi st on

i ndi cat i on of use

I ndi cat e oi l -condi t i on

i nspect i on dat e

oi l - l evel gauget her mome

t er

Pai nt ar ea ar ound ai r

br eat her s i n whi t e, and

al ways keep cl ean

hydr aul i c cyl i nder

sol enoi d val ve

f i l t er

The f our mai n enemi es of hydr aul i c f l ui d

1. Ai r ent r ai nment - no f r ot hi ng.2. For ei gn mat t er ( wat er , dust ,

f or ei gn f l ui ds) - c l ean ai r br eat her s, check f i l t er s, t ake car e when changi ng f l ui d, i nspect and cl ean f l ui d, et c.

3. Hi gh t emper at ur e - t emper at ur e shoul d be bel ow 55 . Al so be ℃car ef ul about di f f er ences i n i nl et and out l et f l ui d t emper at ur es i n heat exchanger s.

4. Leaks - mai nt ai n packi ng and pr event v i br at i on.

Sur f ace damage t o hi gh-pr essur e hoses and wi r i ng. Check f or

scr at ches, cr acks,

di r t , et c.

Fi gur e. Exampl e of Gener al I nspect i on I t ems

Hydr aul i c uni t s

242

Vi sual i zat i on f or t he checki ng r out e

243

t ur nt abl e

capst anpr essur e r ol l er

gui de r ol ler

count er cont r ol panel

gui de r ol l er

pi pe

gui de r ol l er

capst an

capst an

gui de r ol l er

pr essur e r ol l er

r eal i gnment r ol l er

gui de

f el t pad

Suppl y

br ake

c- spool

Make a habi t of doi ng t he best

dr awi ng possi bl e

Bobbi n wi nder

244

No. Item Phenomenon MethodStandar

dEffect on quality Number

Type of control Interval

Department responsible

Recurrence prevention

1 C-spoolsDirt and surface damage

Touch

Check for

anything that feels

unusual

Scratch-es

All ―When return-

ingProduction

2 Felt pads Copper or iron powder

Look Limit sample

　 5 ― Once a day

　

3

Guide and

realign-ment rollers

Faulty rotation Look

Check that

mark is rotating

Scratch-es, faulty winding

14 × 5 ―Once a

day　

Figure Cleaning and Inspection Standard

Quantify so far as possible. If not

possible, check parts using limit samples.

Clarify relation between defect

and equipment.

It is important to indicate the

number to be checked.

Need for accuracy trend

control, etc.

245

I nt er val Mont h 1 Mont h 2 Mont h 3 Ti me r equi r ed

Dai l y

Ever y 10 days

Mont hl y

Ever y 3 mont hs

Appr ox.10 mi n.

15- 20 mi n.

15- 20 mi n.

15- 20 mi n.

246

No. Maintenance itemNo. of

sites

DayPerson responsible

1 2 3 4 30 31

1 FRLsCheck oil level, drain, disassemble and service

7 ● Robinson

2Lubrication of grease nipples

25 　

3 RustPaint, apply corrosion inhibitor ― ● 　

4Leakage (draw maps)

Compressed air, gas, water, oil ― 　

5Scatter (draw maps) Chips, dust, fumes ― 　

6 Sight-glasses Oil level, oil contamination 12 　

Equipment name

Figure Autonomous Maintenance Calendar

Cont ami nat ed i n t wo pl aces

247

Aut onomous mai nt enance cal endar CI L

248

STEP 3. AM Cal endar

STANDARD CODE

COMPONENT

TYPE OF ACTIVITY ACCORDING TO

SUPPLIER’S PROCEDURE



STEP 3. AM Standard Examples

STABILIMENTO: VALLADOLID

U.O. CARROCERÍAS

MÁQUINA: OP20A MASCHERONE

CÓDIGO CICLO:

T. CICLO: INSPECCIÓN LIMPIEZA LUBR

HERRAMIENTAS NECESARIASMATERIAL DE CONSUMODURACIÓN DEL CICLO FRECUENCIA

180 minutos 1 veces cada 2 meses Líquido lubricante

OP20A_1_4

ZONAS DE LUBRICACIÓN DE MESA OP20A

OP 20A BALANCINAS Y MESA DE RODILLOS

SQ22RB

SQ21RB

SQ24RB

SQ23RB

0 SQ37RB SQ26RB

0 SQ38RB MOT VAR DX 0 0 SQ25RB

O.S. DX SQ28RB

0 0 SQ27RB

SQ30RB

0 0 0 0 SQ29RB

C4 C3 SQ32RB

0 0 SQ31RB

RETROCESO M.ELEV.

POS RAL STOP

0 O.SEG2 RETR. 00 0 0 S 0 E. ALTO

0 O.SEG3 AV. 0 CENTR. M.R. 0 0 E. INTERM.

STOP RAL POS O.SEG1 0 B E. BAJO

AVANCE

0 0 SQ11RB

C2 C1 SQ12RB

0 0 0 0 SQ9RB OP20A EN REPOSO

SQ10RB

0 0 SQ7RB LABOR ULTIMADA

O.S. SX SQ8RB

0 SQ18RB MOT VAR SX 0 0 SQ5RB ANOMALIA OP20A

0 SQ17RB SQ6RB

SQ3RB WIP OP20A

SQ4RB

SQ1RB

SQ2RB

STABILIMENTO: VALLADOLID

U.O. CARROCERÍAS

MÁQUINA: OP20A MASCHERONE

CÓDIGO CICLO:

T. CICLO: INSPECCIÓN LIMPIEZA LUBR

HERRAMIENTAS NECESARIASMATERIAL DE CONSUMODURACIÓN DEL CICLO FRECUENCIA

OP20A_1_2

ESTANDAR CODIFICACIÓN COLORES /FRECUENCIA

RED GREEN BLUE YELLOW ORANGE COLOR

SHELL LAMORA 320 KLUBER SYNTHESO D460 EP KLUBER ISOFLEX NBU 15 KLUBERSYNTH GH6-220 LOCTITE 8101 DESCRIPTION

CC 320 CC 460 ------- 220 ------- ISO

75319506 75319506 75261824 ------- 75258328 SAP

WEEKLY MONTHLY BIMONTHLY QUARTERLY SIX-MONTHLY ANNUAL

COLOUR CODE: OIL / GREASE TYPE

SHAPE CODE : FREQUENCY

250

STEP 3. Vi sual Management

251

STEP 3. Vi sual Management

252

STANDARDIZATION OF THE CIL TASK LIST

AFTER

Optimization of the CIL task listOver time due to single 3° step task list without optimization

BEFORE

30 min/week 　 -31% vs actual

253

AM STATUS AND FUTURE VISION

Restore Basic Condition

Become a humansensor

Expand responsibilities

Management byobjectives

Machine 2

Machine 3

Machine 4

Machine 1

PA

C D

PA

C D

People Development

TODAY OUR VISION TOMORROW

254

Step 1-3: results

Costs and Benefits Step 1-3

2221

1684

583

1686

2752

2279

0,0

500,0

1000,0

1500,0

2000,0

2500,0

3000,0

Step 1 Step 2 Step 3

Costi

Benefici

255

Step 1-3: resultsN° of breakdowns due to

the lack of basic conditions

43

00

10

20

0Step 1 Step 2 Step 3

Cleaning and Inspection Time

600

280

36

740

419

117,88

0

100

200

300

400

500

600

700

800

1° STEP 2° STEP 3° STEP 4° STEP 5° STEP

Min

uti/s

ettim

ana

Attività a macchinaferma

Totale attività

Obj=125 min/sett

Scraps / Step

0,40 0,42 0,38

0,000,200,400,600,801,001,201,401,601,802,00


AM Tags

143

238

286

100

150

200

250

300

350

400


256

Step 1-3: results

WHY? Step 3 Step 4

After the implementation of the first

three steps team members have

expressed the desire to improve their

skills through training activities

focused on the main machine

operating groups.

1° INPUT: Residual losses

2° INPUT: People motivation

Total machine losses: Rettifica De Clichy (TG745389)

78%

22%

OEE

Perdite totali

lolosses

LOSSES TO ATTACK WITH AM PILLAR

Scraps and reworks

Maintenance activities

15%

Introduction of new inspections

257

St ep 4: Per f or m Gener al Equi pment I nspect i on

Step 4

258

Step 4: Conduct general equipment inspection

Activities

• Pr ovi de i nspect i on ski l l s t r ai ni ng based on i nspect i on manual s

• Get i ndi v i dual equi pment i t ems i nt o peak condi t i on by subj ect i ng t hem t o gener al i nspect i on

• Modi f y equi pment t o f aci l i t at e checki ng. Make ext ensi ve use of v i sual cont r ol s

259


• I mpr ove r el i abi l i t y by per f or mi ng gener al i nspect i on and r ever si ng det er i or at i on f or each equi pment cat egor y ( nut s and bol t s, dr i ve syst ems, et c. )

• Enabl e anyone t o i nspect r el i abl y by i nt r oduci ng vi sual cont r ol s such as equi pment namepl at es, V- bel t speci f i cat i on di spl ays, l ubr i cant t ype and quant i t y di spl ays, cor r ect oper at i ng r ange pl ays on gauges, val ve on–of f i ndi cat or s, r ot at i on di r ect i on i ndi cat or s, t her mochr omi c t ape, et c.

St ep 4: Conduct gener al equi pment i nspect i on

260


• Lear n equi pment st r uct ur e, f unct i ons, and assessment cr i t er i a and mast er checki ng ski l l s t hr ough hands- on checki ng t r ai ni ng

• Lear n t o deal wi t h equi pment abnor mal i t i es t hr ough on- t he- spot pr act i ce

• Use r el ay t eachi ng t o enabl e l eader s t o l ear n l eader shi p and member s t o devel op t eam spi r i t

• Let peopl e under st and t he usef ul ness of dat a by col l ect i ng gener al i nspect i on dat a


261

Roles of Managers and Staff (fostering motivation, ability, and opportunity)•Pr epar e gener al i nspect i on and t r oubl eshoot i ng case st udi es, and t r ai n gr oup l eader s i n i nspect i on ski l l s•Dr aw up i nspect i on schedul es•Gi ve on- t he- spot t r ai ni ng i n s i mpl e met hods of r ect i f y i ng abnor mal i t i es•Pr ompt l y per f or m wor k r equest ed as a r esul t of exposi ng abnor mal i t i es•Gi ve gui dance i n i mpr ovi ng vi sual cont r ol s•Gi ve i nst r uct i on i n dat a col l ect i on and anal ysi s•I nvol ve gr oup l eader s i n mai nt enance pl anni ng


262


1. Educat i on:


1. Conduct gener al educat i on.2. Conduct speci f i c educat i on.3. Conduct a compr ehensi ve t est .

2. I nspect i ve i t ems:• Pr epar e i nspect i ng check

l i s t s .• Assess i nspect i ve i t ems.

3. I nspect i ve:• Conduct an over al l

i nspect i on.• Remedy def ect i ve ar eas

di scover ed.

263


4. Set t ent at i ve i nspect i ng st andar ds.

5. Est i mat e i nspect i ng i nt er val s.

6. Set i nspect i ng t i me t ar get s.

7. Set i mpr ovement t ar get s.

8. Di f f i cul t i nspect i on ar ea:


• I dent i f y di f f i cul t i nspect i ng ar eas.

• Remedy di f f i cul t i nspect i ng ar eas.

264


9. Revi ew i nspect i ng t asks.

10. Al l ocat e r out i ne i nspect i ng ski l l .

11. Check oper at or s’ i nspect i ng ski l l .




265

1. Basic knowledge of equipment

* How far knowledge is necessary?

(Clarification of the range of knowledge)

2. Training / Education* How much have the operators understood?

(Confirmation test)

3. Visual management* Easy to inspect* Easy to find abnormalities

How t o car r y out gener al i nspect i on

266

Devel opi ng equi pment - compet ent oper at or s

Devel opi ng equi pment - compet ent oper at or s

r evol ut i oni zes not j ust equi pment but ever y ot her

aspect of wor kpl ace management as wel l .

267

Pr epar i ng f or gener al i nspect i on t r ai ni ng

Sel ect gener al i nspect i on i t ems.

Pr epar e mat er i al s f or gener al i nspect i on t r ai ni ng.

Dr af t gener al i nspect i on t r ai ni ng schedul e.

1. Mai nt enance st af f i nst r uct t eam l eader s.

2. Team l eader s pass on t hei r knowl edge t o t eam member s ( r el ay t eachi ng) .

3. Oper at or s per f or m gener al i nspect i on.

4. An audi t i s hel d and t he t eam st andar di zes, or consol i dat es i nspect i on pr ocedur es.

268

Pr ocedur e f or devel opi ng gener al i nspect i on t r ai ni ng pr ogr am

Est abl i sh gener al i nspect i on cat egor i es

Mai nt enance st af f

Pr epar e t r ai ni ng mat er i al s


Schedul e t r ai ni ngMai nt enance st af f

and wor kpl ace super vi sor s

Tr ai n gr oup l eader s


Pr epar e f or “r el ay t eachi ng” ofgr oup member s

Gr oup l eader s; wor kpl ace

super vi sor s

Tr ai n gr oup member s

Gr oup l eader s

Pr epare

Tr ai n

( e. g. , Nut s, bol t s, l ubr i cat i on syst ems, pneumat i cs, hydr aul i cs, dr i ve syst ems, el ect r i cs, et c. )

Checksheet s

Manual s( Cut away model s,

wal l char t s, s l i des, et c. )

( Gener al i nspect i on of model equi pment )

269

Pr ocedur e f or devel opi ng gener al i nspect i on t r ai ni ng pr ogr am

Abnor mal i t i es l i st s( Det er i or at ed par t s;

i naccessi bl e ar eas)

( Gener al i nspect i on of al l equi pment )

Gr oup member s; mai nt enance per sonnel

Conduct gener al i nspect i on

Gr oup member s

Hol d gr oup meet i ngs, l i s t abnor mal i t i es, pl an act i ons

Gr oup l eader s

Per f or m sel f - audi t and appl y f or of f i c i al audi t

Gr oup l eader s

Tr eat pr obl em ar eas i ndi cat ed

Cor r ect abnor mal i t i esGr oup member s;

mai nt enance per sonnel

Est abl i sh pr ovi s i onal dai l y i nspect i on st andar ds

Gr oup member s

Assess i nspect i on ski l l s

Gr oup member s

Per f or m audi tWor k pl ace

super vi sor s; mai nt enance st af f

Gener al I nspect

i on

Gener al I nspect i on

Rei nf or cement

Pr ovi s i onal st andar ds( On compl et i on

of each cat egor y)

Ski l l s assessment char t s

( Pr act i cal t est s)

Move t o nest i nspect i on cat egor y ( appr oxi mat el y one

cat egor y per mont h)

270

Sampl e schedul e f or mat f or gener al i nspect i on t r ai ni ng

Cat egor y Mont h 1 Mont h 2 Mont h 3 Mont h 4

Nut s and bol t s

①　　　②　　　　　　 ③　　　　　　　　　　④

Lubrication

①　　　②　　　　　　③　　　　　　　　　　④

Transmissions

①　　　②　　　　　　③　　　　　　　　　　④

Pneumatics

①　　　②　　　　　　 ③　　　　　　　　　　④

①Fr om mai nt enance st af f t o gr oup l eader s

②Fr om gr oup l eader s t o gr oup member s

③Gener al equi pment i nspect i on

④Rei nf or cement of gener al i nspect i on cat egor y

271

I mpl ement i ng gener al i nspect i on t r ai ni ng

The i mpor t ance of “r el ay t eachi ng. ”

Tr ai ni ng t eam l eader s.

Pr epar at i on by t eam l eader s.

Rel ay t eachi ng i n pr act i ce.

Conduct i ng t he gener al equi pment i nspect i on.

Consol i dat i on af t er each gener al i nspect i on.

272Fi gur e. The depl oyment of TPM act i on t eams

TPM Depl oymentTPM Pr epar at i on

Teach

Pi l ot Team

Manager ’ sModel Teams

Equi pmentAct i on Teams

Teach

273

Gener al i nspect i on of bol t s and nut s

274

Don’ t f ast en bol t s/ nut s t oo t i ght !

I f t i ght ened t oo much, bol t s easi l y get br oken.

275

Do not i nser t bol t s f r om t he t op!

Over l ook t he l oosened nut .

The l ack of t he nut cannot be f ound.

276

Do not use t hi nner nut s above t hi cker nut s!

Thi s i s t o t i ght t he bol t .

Bol t

Upper nut

Body

Thi s i s not t o move t he upper nut .

277

Gener al i nspect i on of l ubr i cat i on

278

Fr ont gl ass

Do not i ndi cat e t he pr essur e gauge l i mi t s on t he gl ass cover !

279

Never l et t he pr essur e gauge needl e r each t he cent r al r i ght - hand posi t i on!

280

Do not l eave smal l oi l l eakage !

By f i ndi ng causes, we wi l l be abl e t o i ncr ease t he mai nt enance l evel .

281

Gener al i nspect i on of hydr aul i c/ pneumati c devi ces

282

Concr et e exampl e of i nspect i on ３ Hydr aul i c ３ Uni t

( 1) Check wi t h “ eyes”

　 Ar e hydr aul i c uni t s not cont ami nat ed by chi ps and cut t i ng oi l ?

　 I sn’ t t her e any oi l l eakage f r om pumps, el ect r omagnet i c val ues or j oi nt s?

　 Ar e pr essur e gauges pr oper ones? 　 Does i t keep a r i ght val ue? 　 Ar e t he t ypes and capaci t i es of t he pump and

t he mot or appr opr i at e? 　 I s t he oi l l evel gauge c l ear ? 　 Ar e t he quant i t y and t he col or of oi l pr oper ? 　 I s t he cap of t he oi l suppl y out l et c l osed

pr oper l y? 　 Ar e t her e any spaces or hol es i n t he mai n body

of t he t ank, f r om whi ch dust may come i n? 　 I sn’ t t he l eaked oi l r et ur ned t o t he t ank?

283

( 2) Check wi t h “ ear s” 　 Ar e t her e any r oar i ng sounds pr oduced f r om pumps,

mot or s, t he el ect r o- magnet i c val ues or pi pes?

( 4) Check wi t h “ hand” by t ouchi ng sur f aces 　 I s t her e any v i br at i on or gener at ed heat f r om pumps,

mot or s or el ect r o- magnet i c val ves? 　 Ar e t he l ock i ng nut s of pumps, mot or s or el ect r o-

magnet i c val ves not l oosened? 　 Check oi l l eakage by wi pi ng t he ar ea. 　 Ar e t he pi pes i nt er sect ed or cont act ed wi t h each

ot her ?

( 6) Check by r emovi ng 　 How i s t he wear of cupl i ngs of mot or s and pumps? 　 Ar e t he ai r br eat her s of oi l suppl y out l et caps

appr opr i at e? 　 Ar e t he oi l s t r ai ner s of oi l suppl y out l et s not t or n

or f ul l of dust ? 　 I s t her e any dust accumul at ed i n t anks? 　 Ar en’ t suct i on f i l t er s c l ogged wi t h dust and di r t ?

284

Do not t wi st hoses !

When t her e i s t wi st , a punct ur e t akes pl ace.

No t wi st

285

Do not use hoses i n a st r et ched st at e!

Fl exi bl e

286

Do not bend hydr aul i c hoses t oo much!

287

Do not br i ng oi l t emper at ur e above 60 degr ees i n t he hydr aul i c t ank !

Need a cool er

Ri ght zone

Need at t ent i on at t he t i me of st ar t up

288

Gener al i nspect i on of power t r ansmi ssi on

289

Do not al l ow a chai n t o be sl acki ng mor e t han 2% of t he di st ance bet ween t he t wo axes !

The di st ance

Dr i v i ng

si de

290

Concr et e exampl e of i nspect i on : Dr i vi ng Uni t s( 1) Check wi t h “ eyes” 　 Ar e t he mot or s and r educt i on gear s not cont ami nat ed

by chi ps and oi l ? 　 Ar e bel t s not l oosened? I s t he t ensi on nor mal ? 　 Ar e t he oi l l evel gauges of r educt i on gear s c l ean? 　 I s i t easy t o check bel t s or t he pul l eys? ( 3) Check wi t h “ ear s” 　 Ar e t her e any r oar i ng sounds or s l i ppi ng sounds

pr oduced f r om mot or s, r educt i on gear s, bel t s or chai ns?( 5) Check wi t h “ hand” by t ouchi ng dur i ng oper at i on 　 I s t her e any v i br at i on or gener at ed heat f r om mot or s

or r educt i on gear s?( 7) Check by s t oppi ng t he oper at i on or by t ouchi ng wi t h

hand 　 Ar e t he quant i t y and t he col or of oi l of r educt i on

gear s pr oper ? 　 Ar e saf et y cover s pr oper l y equi pped? 　 Ar e bol t s of mot or s and r educt i on gear s not

l oosened?

291

( 5) 　 Check by r emovi ng 　 I s bel t t ensi on pr oper ? 　 Ar e t he t ypes and t he number of bel t s and pul l eys pr oper ? 　 Ar e bel t s and pul l eys not wor n? 　 Ar e bol t s and keys of pul l eys not l oosened? 　 Ar e bel t s bet ween pul l eys st abl e? 　 Ar e mot or s and r educt i on gear s connect ed pr oper l y? 　 Ar e t he cupl i ngs bet ween a mot or and a r educt i on gear not wor n? 　 Ar en’ t mot or s and ai r cool i ng f ans c l ogged wi t h dust ? 　 I s t her e dust i n t he l ubr i cat i on oi l of r educt i on gear s?

292

Do not di r ect st oppi ng cl i ps of a chai n t owar ds t he r ot at i ng di r ect i on !

Movi ng di r ect i on

293

Do not al l ow a chai n t o j ump over a t oot h of a spr ocket !

NewWor n

294

Do not gr ease chai ns, use oi l !

Rol l er

Pi n

Bush

295

Char ge oi l t o a chai n at t he l oosened si de.

Oi lDr i v i ng si de

296

Do not use V bel t s i n t he si t uat i ons of ②, and i n t he f i gur e! ③ ④

For ei gn body

Wor n pul l ey

Wor n bel t

297

Do not change one bel t onl y! Repl ace al l t he bel t s at t he same t i me!

298

Do not al l ow V bel t s t o vi br at e l at er al l y !

When bear i ngs ar e hot , bel t t ensi on i s t oo hi gh. When t he pul l eys ar e hot , bel t

t ensi on i s t oo l ow. Sl i ps t ake pl ace.

The causes of l at er al v i br at i on :

• Eccent r i c i t y

• Wear

• Looseness

299

Gener al i nspect i on

of el ect r i ci t y

300

Do not over l ook r educed pr essur e of an ai r set of t hr ee uni t s !

301

Do not put t he l ower l i mi t of t he oi l er bel ow t he hei ght of t he suct i on pi pe!

I n

Mi st

Ai r pr essur e

Suct i on pi pe

302

Do not l eave ai r l eakage of an ai r set of t hr ee uni t s !

Ai r l eakage t akes pl ace at t he f ol l owi ng poi nt s :

1. Joi nt bet ween t he uni t s

2. Ai r r el i ef hol e of a pr essur e r educt i on val ve

3. Gasket of t he case

4. Damaged case

5. Damaged gauge gl ass

6. Oi l char ge pl ug of t he oi l erGasket

Scr ewSi ght gl ass

Oi l pl ug

Gasket

Gauge gl ass

Case

Out

Rel i ef hol e

Dr ain l ock

Case

303

( 1) . Checkpoi nt s f or nut s and bol t s

Sl i ght Def ect s • Ar e any nut s or bol t s l oose?• Ar e any nut s and bol t s mi ssi ng?

Bol t Lengt hs • Do al l bol t s pr ot r ude f r om nut s by 2- 3 t hr ead l engt hs?

Washer s • Ar e f l at washer s used on l ong hol es?• Ar e t aper ed washer s used on angl e bar s and

channel s?• Ar e spr i ng washer s used wher e par t s ar e

subj ect t o v i br at i on?• Ar e i dent i cal washer s used on i dent i cal

par t s?

At t achment of Nut s and Bol t s

• Ar e bol t s i nser t ed f r om bel ow, and ar e nut s v i s i bl e f r om t he out si de?

• Ar e devi ces such as l i mi t swi t ches secur ed by at l east t wo bol t s?

• Ar e wi ng nut s on t he r i ght way ar ound?

304

( 2) . Lubr i cat i on checkpoi nt s

Lubr i cant St or age • Ar e l ubr i cant st or es al ways kept c l ean, t i dy, and wel l - or gani zed by t hor ough appl i cat i on of t he 5S pr i nci pl es?

• Ar e l ubr i cant cont ai ner s al ways capped?• Ar e l ubr i cant t ypes cl ear l y i ndi cat ed and

i s pr oper st ock cont r ol pr act i ced?

Lubr i cant I nl et s • Ar e gr ease ni ppl es, speed- r educer l ubr i cant por t s, and ot her l ubr i cant i nl et s al ways kept c l ean?

• Ar e l ubr i cant i nl et s dust pr oof ed?• Ar e l ubr i cant i nl et s l abel ed wi t h t he

cor r ect t ype and quant i t y of l ubr i cant ?

305

( 2) . Lubr i cat i on checkpoi nt s

Oi l - l evel Gauges • Ar e oi l - l evel gauges and l ubr i cat or s al ways kept c l ean, and ar e oi l l evel s easy t o see?

• I s t he cor r ect oi l l evel c l ear l y mar ked?• I s equi pment f r ee oi l l eaks, and ar e oi l

pi pes and br eat her s unobst r uct ed?

Aut omat i c Lubr i cat i ng Devi ces

• Ar e aut omat i c l ubr i cat i ng devi ces oper at i ng cor r ect l y and suppl yi ng t he r i ght amount of l ubr i cant ?

• Ar e any oi l or gr ease pi pes bl ocked, cr ushed or spl i t ?

Lubr i cat i on Condi t i on

• Ar e r ot at i ng par t s, s l i di ng par t s, and t r ansmi ssi ons ( e. g. chai ns) al ways cl ean and wel l - oi l ed?

• Ar e t he sur r oundi ngs f r ee of cont ami nat i on by excess l ubr i cant ?

306

( 3) . Tr ansmi ssi on syst em checkpoi nt s

V- bel t s and Pul l eys

• Ar e any bel t s cr acked, swol l en, wor n, or cont ami nat ed by oi l or gr ease?

• Ar e any bel t s t wi st ed or mi ssi ng?• Ar e any bel t s st r et ched or s l ack?• Ar e mul t i pl e bel t s under uni f or m t ensi on and

al l of t he same t ype?• Ar e t op sur f aces of bel t s pr ot r udi ng above

t he pul l ey r i ms? Ar e t he bot t oms of any pul l ey gr ooves shi ny ( i ndi cat i ng a wor n bel t or pul l ey) ?

• Ar e pul l eys cor r ect l y al i gned?

Rol l er Chai ns • Ar e any chai ns st r et ched ( i ndi cat i ng wor n pi ns or bushi ngs) ?

• Ar e any spr ocket t eet h wor n, mi ssi ng, or damaged?

• I s l ubr i cat i on bet ween pi ns and bushi ngs suf f i c i ent ?

• Ar e spr ocket s cor r ect l y al i gned?

307

( 3) . Tr ansmi ssi on syst em checkpoi nt s

Shaf t s ３ Bear i ngs ３ and Coupl i ngs

• I s t her e any over heat i ng, v i br at i on, or abnor mal noi se due t o excessi ve pl ay or poor l ubr i cat i on?

• Ar e any keys or set bol t s l oose or mi ssi ng?• Ar e any coupl i ng mi sal i gned or wobbl y?• Ar e any coupl i ng seal s wor n? Ar e any bol t s

s l ack?

Gear s • Ar e gear s pr oper l y l ubr i cat ed wi t h t he r i ght amount of l ubr i cant ? Ar e t he sur r oundi ngs cl ean?

• Ar e any t eet h wor n, mi ssi ng, damaged, or j ammed?

• I s t her e any unusual noi se or v i br at i on?

308

( ３ ) . Hydr aul i c checkpoi nt s

Hydr aul i c Uni t s

• I s t he cor r ect quant i t y of f l ui d i n hydr aul i c r eser voi r s, and i s t he cor r ect l evel i ndi cat ed?

• I s f l ui d at t he cor r ect t emper at ur e? Ar e t he maxi mum and mi ni mum per mi ssi bl e t emper at ur es i ndi cat ed?

• I s f l ui d c l oudy ( i ndi cat i ng ai r ent r ai nment ) ?• Ar e al l f l ui d i nl et s and st r ai ner s c l ean?• Ar e any suct i on f i l t er s bl ocked?• Ar e any f l ui d r eser voi r br eat her f i l t er s

bl ocked?• Ar e al l f l ui d pumps oper at i ng nor mal l y wi t hout

any unusual noi se or v i br at i on?• Ar e hydr aul i c pr essur es cor r ect , and ar e

oper at i ng r anges cl ear l y di spl ayed?

Heat Exchanger s

• I s any f l ui d or wat er l eaki ng f r om f l ui d cool er s or pi pes?

• Ar e t emper at ur e di f f er ences bet ween f l ui d and wat er i nl et s and out l et s cor r ect ? Ar e any t ubes bl ocked?

309

( ３ ) . Hydr aul i c checkpoi nt s

Hydr aul i c Equi pment

• Ar e t her e any f l ui d l eaks?• Ar e hydr aul i c devi ces pr oper l y secur ed

wi t hout any makeshi f t f ast eni ngs?• Ar e hydr aul i c devi ces oper at i ng cor r ect l y

wi t hout speed l osses or br eat hi ng?• Ar e hydr aul i c pr essur es cor r ect , and ar e al l

pr essur e gauges wor ki ng cor r ect l y ( zer o poi nt s, def l ect i on) ?

Pi pi ng and Wi r i ng

• Ar e al l pi pes and hoses secur el y at t ached?• Ar e t her e any f l ui d l eaks? Ar e any hoses

cr acked or damaged?• Ar e al l val ves oper at i ng cor r ect l y? I t i s

easy t o see whet her val ves ar e open or shut ?• Ar e any pi pes, wi r es, or val ves unnecessar y?

310

( 5) . Pneumat i c checkpoi nt s

FRLs • Ar e FRLs al ways kept c l ean? I s i t easy t o see i nsi de t hem? Ar e t hey f i t t ed t he r i ght way ar ound?

• I s t her e suf f i c i ent oi l , and ar e t he dr ai ns cl ear ?

• I s t he oi l dr i p r at e cor r ect ( appr oxi mat el y 1 dr op f or ever y 10 st r okes) ?

• Ar e FRLs i nst al l ed no mor e t han 3 m f r om t he pneumat i c equi pment ?

• Ar e pr essur es adj ust ed t o t he cor r ect val ue and ar e oper at i ng r anges cl ear l y i ndi cat ed?

311

( 5) . Pneumat i c checkpoi nt s

Pneumat i c Equi pment

• I s any compr essed ai r l eaki ng f r om pneumat i c cyl i nder s or sol enoi d val ves?

• Ar e al l pneumat i c cyl i nder s and sol enoi d val ves f i r ml y at t ached?

• Ar e any makeshi f t f i x i ngs i n use ( wi r e, adhesi ve t ape, et c. ) ?

• Ar e any pi st ons di r t y, wor n, or damaged?• Ar e speed cont r ol l er s i nst al l ed t he r i ght

way ar ound?• I s t her e any abnor mal noi se or over heat i ng

of sol enoi d val ves, and ar e any l ead wi r es chaf ed or t r ai l i ng?


• Ar e t her e any pl aces i n pneumat i c pi pes or hoses wher e f l ui d i s l i abl e t o col l ect ?

• Ar e al l pi pes and hoses cl i pped f i r ml y i nt o pl ace?

• Ar e t her e any compr essed- ai r l eaks? Ar e any hoses cr acked or damaged?

• Ar e al l val ves oper at i ng cor r ect l y? I s i t easy t o see whet her val ves ar e open or c l osed?

• Ar e any pi pes, wi r es, or val ves unnecessar y?

312

( 6) . El ect r i cal checkpoi nt s

Cont r ol Panel s • Ar e t he i nt er i or s of di st r i but i on boar ds, swi t chboar ds, and cont r ol panel s kept c l ean, t i dy and wel l - or gani zed by t he appl i cat i on of t he 5S pr i nci pl es? Have any ext r aneous obj ect s or f l ammabl e mat er i al s been l ef t i nsi de?

• I s t he wi r i ng i nsi de cont r ol panel s i n good condi t i on? Ar e any wi r es coi l ed or r ai l i ng?

• Ar e al l ammet er s and vol t met er s oper at i ng cor r ect l y and cl ear l y mar ked?

• Ar e any i nst r ument s or di spl ay l amps br oken? Ar e any bul bs f aul t y?

• Ar e any swi t ches br oken? Do al l swi t ches wor k cor r ect l y?

• Ar e cont r ol panel door s i n good condi t i on? Do t hey open and cl ose easi l y?

• Ar e t her e any unused hol es? Ar e cont r ol panel s wat er pr oof and dust pr oof ?

313


El ect r i cal Equi pment

• Ar e al l mot or s f r ee of over heat i ng, v i br at i on, and unusual noi se and smel l s?

• Ar e al l mot or cool i ng f ans and f i ns c l ean?• Ar e any at t achment bol t s l oose? Ar e

pedest al s f r ee of cr acks and ot her damage?

Sensor s • Ar e al l l i mi t swi t ches cl ean and f r ee of excessi ve pl ay?

• Ar e t he i nt er i or s of al l l i mi t swi t ches cl ean? Ar e any wi r es t r ai l i ng? Ar e al l cover s i n good condi t i on?

• Ar e any l i mi t swi t ches i ncor r ect l y i nst al l ed?

• Ar e any l i mi t swi t ch dogs wor n, def or med, or t he wr ong shape?

• Ar e al l phot oel ect r i c swi t ches and pr oxi mi t y swi t ches cl ean and f r ee of excessi ve pl ay?

• Ar e any sensor s out of posi t i on? Ar e cor r ect posi t i ons cl ear l y i ndi cat ed?

• Ar e al l l ead wi r es unchaf ed, and i s i nsul at i on i nt act at ent r y poi nt s?

314


Swi t ches • Ar e al l manual s swi t ches cl ean, undamaged, and f r ee of excessi ve pl ay?

• Ar e al l swi t ches i nst al l ed i n t he cor r ect posi t i on?

• Ar e emer gency st op swi t ches i nst al l ed i n appr opr i at e l ocat i ons, and ar e t hey wor ki ng cor r ect l y?


• Ar e any pi pes, wi r es, or power l eads l oose or unsecur ed?

• Ar e any gr ound wi r es damaged or di sconnect ed?

• Ar e any pi pes cor r oded or damaged? Ar e t her e any bar e wi r es or wi r es wi t h damaged i nsul at i on?

• Ar e any wi r e coi l ed on t he f l oor or dangl i ng over head?

315

( 7) . Checkpoi nt s f or gener al - pur pose equi pment

Pumps

• Ar e pumps and t hei r st ands f r ee of unusual noi se, v i br at i on, and pl ay?

• Ar e pedest al bol t s t i ght , cor r osi on- f r ee, and undamaged?

• Ar e st ands and pedest al s f r ee of cor r osi on, cr acki ng and ot her damage?

• I s any l i qui d l eaki ng or spr ayi ng f r om gl and packi ngs?• I s any l i qui d l eaki ng or spr ayi ng f r om pi pes or

val ves?• Ar e any pi pes or val ves bl ocked?• Ar e al l pr essur e gauges, vacuum gauges, f l owmet er s,

t her momet er s, and ot her measur i ng i nst r ument s wor ki ng pr oper l y and mar ked wi t h t he cor r ect oper at i ng r anges?

• Ar e st ar t i ng cur r ent and oper at i ng cur r ent val ves cor r ect ? Ar e t hese cl ear l y i ndi cat ed?

• Ar e al l val ves oper at i ng cor r ect l y? I s i t easy t o see whet her whet her val ves ar e open or c l osed?

316

( 7) . Checkpoi nt s f or gener al - pur pose equi pment

Fans • Ar e f ans and t hei r st ands f r ee of unusual noi se, v i br at i on, and pl ay?

• Ar e al l pedest al bol t s t i ght , cor r osi on- f r ee, and undamaged?

• Ar e al l st ands and pedest al s f r ee of cor r osi on, cr acki ng, and ot her damage?

• Ar e any gl and packi ngs l eaki ng ai r or gas?• Ar e any dust s or damper s l eaki ng ai r or gas?• Ar e any dust s bl ocked or c l ogged?• Ar e al l pr essur e gauges, vacuum gauges, f l owmet er s,

t her momet er s, and ot her measur i ng i nst r ument s wor ki ng pr oper l y and mar ked wi t h t he cor r ect oper at i ng r anges?

• Ar e st ar t i ng cur r ent and oper at i ng cur r ent val ues cor r ect ? Ar e t hese cl ear l y i ndi cat ed?

• Ar e al l damper s oper at i ng cor r ect l y? I s i t easy t o see whet her damper s ar e opened or c l osed?

317

Step 4: General Inspection

Costs- Inspection and cleaning activities - Training

- Losses in productivity

Benefits- Further reduction of losses (scraps) and consequent increase of OEE - Reduction of inspection activities made by professional maintenance team

Step 4 Costs and Benefits Evaluation

1561,38

2426,69

0

500

1000

1500

2000

2500

3000

1

Costi

Benefici

1500

2400

318


Machine decomposition

Operating groups

Inspection cards

Training room

Practical Training

9 trained people

27 total training hours

OPL



Step 0. Basic training: Operators’ Knowledge and Skills - example

INITIAL STATE

CURRENT STATE

TR

AIN

ING

req

ue

rid

o

act

ua

l

.1 Mantenim iento Mecánico 2 2

.2 Mantenim iento Eléctr ico 2 2

.3 Mantenim iento Neum át ico 2 2

.4 Act ividades autonom as 3 3

.5 W CM 3 3

.6 Herram ientas de Calidad 3 3

.7 Logist ica 2 2

PI LARES

Tecnólogo

0

1

2

31

2

3

45

6

7

requerido

actual

320

Annual substitution costs PX

407 €

37

- €

50 €

100 €

150 €

200 €

250 €

300 €

350 €

400 €

450 €

Step 1-3 Step 4

Example of training efficiency

BEFORE AFTER

Monthly substitution of the component following

to collisions for wrong assembly

Correct assembly

Component substitution at the end of its life-cycle

COMPONENT: PROXIMITY

COMPONENT COST: 37 €

321

2006 2007

Fatality 0 0

0 0

0 0

0 0

0 0

1 5

FATALITY

NEAR MISSES

FAI

LWDC > 3 DAYS

LWDC ≤ 3 DAYS

UNSAFE ACTS AND CONDITIONS


Quality Inspections

Quality Correlation Matrix

Safety Inspections

Component Inspections

From product control to process control

New unsafe act and conditions identified

Heinrich Pyramid

322


Usura punta da contatto per mancata lubrificazione

Controllo bloccaggio della contropunta mediante manometro

Quality inspections allowed to identify abnormalities on equipment.

323

Step 4: results


600

280

36 59,19

740

419

117,88

192,81

0

100

200

300

400

500

600

700

800


Min

uti/

sett

iman

a


Totale attività

Obj=210 min/sett

Costs and Benefits / Step

2221

1684

583

14191686

2752

22792022

0

1000

2000

3000

Step 1 Step 2 Step 3 Step 4

STEP

€

CostiBenefici

Scraps / steps

0,40 0,42 0,380,26

0,00

0,200,400,600,801,001,201,401,601,802,00


AM Tags

143

238

286302

100

150

200

250

300

350

400


324

Step 4: results

WHY? Step 4 Step 5

Total machine losses: Rettifica De Clichy (TG745389)

84,5%

15,5%

OEE

Perdite totali

LOSSES TO ATTACK WITH AM PILLAR


5%

Reduction of cleaning and inspection times

325

St ep 5: Per f or m Gener al Pr ocess I nspect i on

Sep 5

326

St ep 5: Per f or m gener al pr ocess i nspect i on

Activities

• Pr ovi de i nst r uct i on i n pr ocess per f or mance, oper at i on, and adj ust ment and i n met hods of handi ng abnor mal i t i es i n or der t o i mpr ove oper at i onal r el i abi l i t y by devel opi ng pr ocess- compet ent oper at or s

• Pr event i nspect i on dupl i cat i ons and omi ssi ons by i ncor por at i ng pr ovi s i onal c l eani ng and i nspect i on st andar ds f or i ndi v i dual equi pment i t ems i nt o per i odi c i nspect i on and r epl acement st andar ds f or ent i r e pr ocesses or ar eas

327


• I mpr ove t he over al l st abi l i t y and saf et y of pr ocess t hr ough cor r ect oper at i on

• Shar pen pr ocess i nspect i on pr eci s i on by ext endi ng and i mpr ovi ng vi sual cont r ol s, e. g. , i ndi cat or s f or pi pe cont ent s and f l ow di r ect i ons

• Modi f y equi pment t o make i t easi er t o oper at e


328


• Enabl e oper at or s t o oper at e pr ocesses and deal wi t h abnor mal i t i es cor r ect l y

• Enabl e oper at or s t o under st and t he r el at i onshi p bet ween equi pment and t he pr oper t i es of t he mat er i al s bei ng pr ocessed and mast er t he cor r ect adj ust ment and set t i ng t echni ques

• Make oper at or s awar e of t hei r r ol es i n pl anned mai nt enance and f ost er sel f - management t hr ough per i odi c i nspect i on and r epl acement

• Hel p oper at or s r eal i ze t he necessi t y f or r ecor di ng t i me- ser i es dat a


329


• Prepare general process inspection manuals and troubleshooting manuals, and train group leaders in inspection skills

• Provide on-the-job training in the correct adjustment and setting procedures

• Give guidance on selecting periodic inspection and replacement items, techniques, and documentation, and give instruction on setting appropriate intervals based on hard data

• Prevent planned maintenance duplications and omissions by clearly delineating the operating and maintenance departments’ responsibilities


330


1. Revi ew r esi dual i ssues l ef t f r om St eps 1 t hr ough


2. Pr obl ems:1. I dent i f y pr obl ems i n

c l eani ng. l ubr i cat i ng st andar ds set i n st ep 3 and cat egor i cal i nspect i ng st andar ds set i n St ep 4.

1. Pl an Exami ne causes.2. r emedi al act i ons.3. Take r emedi al act i ons.4. Eval uat e r esul t s of act i ons.

3. Br eakdowns and mi nor st oppages:

331


4. I nspect i on


1. Set t ent at i ve r out i ne i nspect i ng s t andar ds.

2. Compar e wi t h mai nt enance st andar ds set by f ul l - t i me mai nt enance.

3. Set i nspect i ng t i me t ar get s.4. Set t ent at i ve r out i ne

i nspect i ng schedul es.5. Conduct r out i ne i nspect i on.

5. Revi ew cl eani ng, l ubr i cat i ng/ i nspect i ng st andar ds

332



6. Set aut onomous mai nt enance st andar ds and schedul es.



333

Aut onomous i nspect i on

What i s t he r ol e of aut onomous i nspect i on?

Structural drawingLubrication system

This is the most import-ant check point !

Breakdowns can be avoided if you check this point.

If the check point is well known.Right inspection can be carried out !

Equipment can be restored by the periodic repair !

What i s t he r ol e of gener al pr ocess i nspect i on

334

Gener al pr ocess i nspect i on Make usabl e st andar⇒ds

335

Pr ocedur e f or devel opi ng t he pr ocess i nspect i on t r ai ni ng pr ogr am

St ep 5- 1: Cor r ect oper at i on and mani pul at i on.

St ep 5- 2: Cor r ect adj ust ment and set t i ng.

St ep 5- 3: Cor r ect handi ng of abnor mal i t i es.

336

Pr ocedur e f or i mpl ement i ng gener al pr ocess i nspect i on

Cor r ect oper at i onand mani pul at i on

I mpr oved pr ocess st abi l i t y and saf et y

St ep 5- 1

Cor r ect adj ust mentand set t i ng

St ep 5- 2

Cor r ect handi ng of abnor mal i t i es

St ep 5- 3

Pr epar e per f or mance and f unct i on

l essons

Pr epar eoper at i on

manual s

Rel ay OJTSt af f -

gr oup l eader s-gr oup member s

Rel ayt eachi ng

St af f -gr oup l eader s-gr oup member s

Rei nf or ce( pr act i cal

t est s)

Rei nf or ce( i ndi v i dual

t est s)

I dent i f yadj ust ment

and set t i ngkeys

Est abl i shcur r i cul um uni t s

f or chemi calengi neer i ng

basi cs

Pr epar eadj ust ment /

set t i ng manual s

Pr epar el esson sheet s

Rei nf or ce( pr act i cal

t est s)

I dent i f y l i kel ysour ce of

ser i ous acci dent s

Cl ar i f yr esponsi bi l i t y f or

per i odi c checksand par t s

r epl acement

Pr epar e manual son abnor mal s i gns

and phenomena

Pr epar e over haulchecki ng and

par t s r epl acementmanual s

Pr omptdet ect i on

Emer -gency

measur es

Pr edi ct i onand

pr even- t i on

St andar d-i zat i on

andpl anni ng

Rel ay OJTSt af f -


Rel ay OJTSt af f -


Rei nf or ce( i ndi v i dual

t est s)

Rel ay t eachi ngSt af f -


Rel ay t eachi ngSt af f -


337

Pr epar i ng f or gener al pr ocess i nspect i on

Est abl i sh a cur r i cul um uni t f or each equi pment cat egor y.

Pr epar e gener al i nspect i on checkl i st s.

Pr epar e t eachi ng mat er i al s f or gener al pr ocess i nspect i on t r ai ni ng.

• Pr ocess oper at i on and mani pul at i on manual s

• Pr ocess adj ust ment and set t i ng manual s

• Mat er i al and heat bal ances

• Basi c chemi cal engi neer i ng l esson sheet s

• Tr oubl eshoot i ng sheet s

• Per i odi c over haul i nspect i on manual s

338

Sampl e gener al i nspect i on checkl i st f or mat s

I t em #

Pr ocess composi t i on ( equi pment )

Per f or mance Funct i on

Rol eSpecs.

Rel at i on t o

qual i t y

Why necessar y?

Any l osses?

I mpr ovement pr oposal s

( s i mpl i f i cat i on) ( capaci t y i ncr ease)

I t em #

Adj ust ment / set poi nt

TaskChange i n pr oper t i e

s

Cor r ect r ange/

Reasons

Ef f ect on

qual i t y

Act i on i n event of

abnor mal i t yWhy?What

?How?

I t em #

Past occur r ences Exampl e/ l ocat i on

Dat e/ Fr equency

Pr obl em descr i pt i on

Anal ysi s

( why di d i t happen?)

Recur r ence pr event i on pr oposal

I t em #

Li kel y equi pment / par t

Ant i c i pat ed acci dent / di sast

er

War ni ng si gns/ phenomen

a

Pr oj ect ed l oss/ damage

Cor r ect act i on

St ep 5- 1: Per f or mance and Funct i ons Checkl i st

St ep 5- 2: Adj ust ment and Set t i ng Checkl i st

St ep 5- 3: Checkl i st Pr ocess Pr obl ems and Human Er r or

St ep 5- 4: Checkl i st f or Ant i ci pat i ng Ser i ous Acci dent s

339

Gener al pr ocess i nspect i on t r ai ni ng

I mpl ement gener al pr ocess i nspect i on t r ai ni ng.

Consol i dat e gener al i nspect i on t r ai ni ng.

• Assess ski l l s .

• Set act i on cr i t er i a.

• Pr epar e mai nt enance pl ans.

• Const r uct a r ecur r ence- pr event i on syst em.

340

St r eami ng aut onomous mai nt enance st andar ds

Pr ovi si onal Dai l y Cl eani ng,Checki ng and l ubr i cat i ng St andar ds

•Tr ansf er pr essur e gauges, ammet er s, over heat i ng, abnor mal noi se, v i br at i on, et c. t o newl y f or mul at ed pat r ol checki ng st andar ds

•Tr ansf er V- bel t s, chai ns, coupl i ngs, and ot her i t ems i nspect ed and ser vi ced ever y f ew mont hs t o newl y f or mul at ed per i odi c checki ng st andar ds

•Tr ansf er i t ems wi t h a l ubr i cat i on i nt er val of 3 mont hs or mor e t o newl y f or mul at ed per i odi c l ubr i cat i ng st andar ds

•Tr ansf er c l eani ng f r om t hese st andar ds and t o newl y f or mul at ed annual c l eani ng cal endar

Pat r ol Checki ng St andar ds

•For mul at e checki ng st andar ds and di spl ay on boar ds i n t he wor kpl ace•Pl an and si gnpost t he pat r ol r out e•I mpr ove vi sual cont r ol s and ext end t o al l equi pment and measur i ng i nst r ument s

Per i odi c Checki ng and Lubr i cat i ng St andar ds

•For mul at e checki ng st andar ds f or each cat egor y i n t he 4- st ep t r ai ni ng pr ogr am•For mul at e l ubr i cat i ng st andar ds based on t he 4- st ep t r ai ni ng pr ogr am•I mpr ove ef f i c i ency – r ef i ne i mpr ovement of i naccessi bl e pl aces

Annual Cl eani ng Cal endar

•Pr epar e cal endar based on pr ovi s i onal c l eani ng st andar ds•Ext end cl eani ng i nt er val s – r ef i ne i mpr ovement of cont ami nat i on sour ces

341

Fr om "Cont r ol by Resul t s" t o " Cont r ol by Causes"

Breakdown!

Abnormal noise?

When a br eakdown has t aken pl ace, when a def eat gas been pr oduced

342

How t o deal wi t h br eakdowns or def ect s t hat have act ual l y t aken pl ace?

I f t he st andar ds have not been r evi sed f or mor e t han hal f a year , t hey ar e dead and usel ess

To use the experience of the breakdown as a lesson to improve the ability to detect abnormality.

Breakdown!

I should learn !

"Standards must be easy to keep."Standards must constantly be checked and revised to improve.

It's difficult to keep the standards.

343

Under st andi ng of i r r egul ar i t y f or i nt er nal det er i or at i on by t he f i ve sense

I f assumpt i ons about t he l i f e span ar e di f f i cul t or scat t er i ng i s i mpossi bl e t o avoi d, t he onl y way i s t o under st and t he sympt oms.

• Wer e t her e any i r r egul ar sympt oms bef or e t he f ai l ur e occur r ed?

• Does t he f ai l ur e have sympt oms or not ?• What k i nd of sympt oms i ndi cat e t he f ai l ur e?• Why can’ t t he f ai l ur e be under st ood i n advance f r om t he sympt oms?

• What must be done t o under st and t he sympt oms of t he f ai l ur e?

• I n or der f or oper at or s t o under st and t he sympt oms of t he f ai l ur e, what k i nd of knowl edge or sk i l l i s necessar y?

344

Check during Operation

Check by Operators' five senses

Measuring by Measurement Tools

It is unusual.

A little feverish.

How t o det ect i nt er nal det er i or at i on

345

* By finding out the changes in the cycle time of the equipment.

* By detecting the abnormal noise of the gear box,

Breakage of the piston packing was revealed.

The inspection of the inside revealed the wear of the gear and bearing.

Exampl es of det ect i ng i nt er nal det er i or at i on

346

Step 5: Autonomous Inspection

Valutazione Costi / Benefici Step 5

241,74

1334,97

0

200

400

600

800

1000

1200

1400

1600

1

Costi

Benefici

240

1300

- Costs- Inspection and cleaning activities - Training

- Losses in productivity

Benefits-Further reduction of losses (maintenance activities) and consequent increase of OEE - Reduction of inspection time through ECRS method- Reduction of inspection activities made by professional maintenance team

347

Step 5: Autonomous Inspection – ECRS Method

ELIMINATE Double or obsolete controls not because of

breakdowns.

Controls of different type only on a component.

COMBINE

REDUCE

SEMPLIFY

Logistics combining controls on the same components, reducing the frequency of the controls on MTBF base.

Methods of control, improving and developing devices of control visibility

348

Step 5: Autonomous Inspection – ECRS Method

Example of reduction of inspection time after tool modification

BEFORE AFTER

Axial hole for oil lubrication flow

Inspection cycle frequency reduction

349

Step 5: results

Costs/Benefits for Step

2221

1684

583

1419

201

1686

27522279

2022

1161

0

2000

4000

Step 1 Step 2 Step 3 Step 4 Step 5

STEP

€

Costi

Benefici


600

280

36 59,1915,00

740

419

117,88

192,81

25

0

100

200

300

400

500

600

700

800


Min

uti

/set

tim

ana


Totale attività

Obj=30 min/sett

% Scraps

0,40 0,42 0,380,26 0,18

0,000,200,400,600,801,001,201,401,601,802,00


AM Tags

143

238

286302 307

100

150

200

250

300

350

400


350

St ep 6: Syst emat i ze Aut onomous Mai nt enance

St ep 6

351

St ep 6: Syst emat i ze aut onomous mai nt enance

Activities

• Achi eve qual i t y mai nt enance and saf et y by est abl i shi ng cl ear pr ocedur es and st andar ds f or dependabl e aut onomous mai nt enance

• I mpr ove set up pr ocedur es and r educe wor k- i n- pr ocess

• Est abl i sh a syst em of sel f - management f or wor k pl ace f l ow, spar es, t ool s, wor k- i n- pr ocess, f i nal pr oduct s, dat a, et c.

352


• Pi npoi nt r el at i onshi ps bet ween equi pment and qual i t y and est abl i sh a qual i t y mai nt enance syst em

• Revi ew and i mpr ove pl ant and equi pment l ayout s

• St andar di ze mai nt enance and cont r ol of t r anspor t equi pment , spar e par t s, t ool s, wor k- i n- cess, f i nal pr oduct s, dat a, passageways, c l eani ng equi pment , and so on, and i nt r oduce vi sual cont r ol s f or ever yt hi ng i n t he wor kpl ace


353


• Expand t he spher e of sel f - management by syst emat i z i ng and st andar di z i ng cont r ol i t ems

• Hel p peopl e under st and t he r el at i onshi p bet ween equi pment and qual i t y and appr eci at e t he i mpor t ance of qual i t y mai nt enance

• By st andar di z i ng wor kpl ace management and col l ect i ng dat a, hel p peopl e under st and t he need f or i mpr ovement s ai med at r ai s i ng st andar ds

• Have manager s and super vi sor s l ear n t hei r t r ue r ol es ( i mpr ovi ng st andar ds and ensur i ng t hey ar e f ol l owed)


354


• Pr epar e syst em- f l ow di agr ams f or pr ocesses and gi ve i nst r uct i on i n st andar di zat i on

• Pr epar e qual i t y mai nt enance manual s t hat syst emat i ze t he r el at i onshi p bet ween equi pment and qual i t y, and use t hese f or i nst r uct i on

• Pr ovi di ng t echni cal suppor t f or t asks such as st andar di z i ng t he f l ow of wor k, and gi ve assi st ance i n per f ect i ng vi sual cont r ol s

• Gi ve educat i on and gui dance i n anal ysi s and i mpr ovement t echni ques such as I E, PM, and QC


355



1. Remedi es f ocused on qual i t y r esul t s1. Del i neat i on of qual i t y assur ance

f l ow di agr am2. Pr ocess qual i t y assessment3. Pr event i ve measur es agai nst

def ect i ve pr oduct out f l ow4. Pr oduct handl i ng5. Can qual i t y def ect s be det ect ed when

t hey occur ?

356



2. Remedi es f ocused on qual i t y causes1. Raw mat er i al cont r ol2. Measur i ng appar at us cont r ol3. Ji g and di e cont r ol4. Machi ni ng condi t i on cont r ol5. Mi st ake- pr oof cont r ol

3. Est abl i shment of pr ocess qual i t y assur ance syst em

357

Or gani zat i on and t i di ness

Cleaning is inspection

358

St ep 7: Pr act i ce Ful l Sel f - management

St ep 7

359

St ep 7: Pr act i ce f ul l sel f - management

Activities

• Evol ve act i v i t i es and st andar di ze i mpr ovement s i n l i ne wi t h company and pl ant pol i c i es and obj ect i ves, and r educe cost s by el i mi nat i ng wor k pl ace wast e

• I mpr ove equi pment f ur t her by keepi ng accur at e mai nt enance r ecor ds ( e. g. , MTBF) and anal yzi ng t he dat a i n t hem

360


• Anal yze dat a i n var i ous ways t o i mpr ove equi pment and r ai se pr ocess r el i abi l i t y, saf et y, mai nt ai nabi l i t y, qual i t y, and oper abi l i t y

• Pr i or i t i ze equi pment i mpr ovement s and ext end equi pment l i f et i mes and checki ng i nt er val s by usi ng har d dat a t o spot weakness


361


• I ncr ease awar eness of management by obj ect i ves and make ever yone t hor oughl y cost - consci ous ( i ncl udi ng mai nt enance cost s)

• Enabl e oper at or s t o per f or m si mpl e r epai r s and equi pment r est or at i on by t r ai ni ng t hem i n r epai r ski l l s

• I ncr ease oper at or s ’ abi l i t y t o r ecor d and anal yze dat a, and have t hem mast er i mpr ovement t echni ques


362


• Expl ai n t he i mpor t ance of management by obj ect i ves

• Gi ve hands- on r epai r ski l l s t r ai ni ng • Pr ovi de t echni cal backup f or equi pment i mpr ovement s, and r ai se oper at or s ’ i mpr ovement ski l l s by i ncl udi ng t hem i n i mpr ovement pr oj ect s

• Gi ve gui dance on st andar di z i ng i mpr ovement s and par t i c i pat i ng i n MP act i v i t i es


363

Step 7 : Practice full self-management

364

The pr oduct i on mai nt enance and t he 10 mi nut es checki ng met hod

365

Pr act ice f ul l sel f -management

Recogni zes si gns of abnor mal i t y ; deal s wi t h abnor mal i t i es cor r ect l y; per f or ms per i odi c over haul checki ng and par t s r epl acement cor r ect l ySyst emat i

c aut onomous mai nt enance

Det ect s abnor mal i t i es pr ompt l y ; t akes emer gency act i on agai nst abnor mal i t i es

Per f or m gener al pr ocess i nspect i on

Under st ands pr oper t i es of mat er i al s bei ng handl ed; per f or ms cor r ect adj ust ment and set t i ngConduct gener al

equi pment i nspect i on

Est abl i sh cl eani ng and checki ng st andar ds

Under st ands pr ocess per f or mance and f unct i ons; oper at es pr ocess cor r ect l yAddr ess cont ami nat i on

sour ces and i naccessi bl e pl aces

Per f or m i ni t i al c l eani ng1

2

3

4

5

6

7

1

2

3

4

Ful l aut onomous mai nt enance

7 St eps f or Devel opi ng Aut onomous Mai nt enance

4 St eps t o Became a Capabl e Oper at or

366

5. Audit Criteria and the Check List of Autonomous Maintenance

367

Aut onomous Mai nt enance Audi t s

Devel opi ng an aut onomous mai nt enance pr ogr am i n st eps,

has t wo advant ages t hat make t he pr ogr am especi al l y

ef f ect i ve:

* Act i v i t i es pr oduce concr et e r esul t s as t hey pr oceed

* Resul t s ar e conf i r med as par t of t he pr ogr am

The si ngl e most i mpor t ant f act or i n t he success of an

aut onomous mai nt enance pr ogr am i s conduct i ng a car ef ul

audi t on compl et i on of each st ep t o conf i r m t he r esul t s

achi eved and poi nt t he di r ect i on f or f ur t her wor k. The

audi t pr ovi des gui dance wher e needed and gi ves peopl e a

sense of achi evement . Whi l e t he st ep- by- st ep appr oach

makes t he pr ogr am easi er f or t eams t o under st and as t hey

pr ogr ess t hr ough i t , t he audi t s ser ve as mi l est ones on t he

j our ney and hel p t o consol i dat e t he gai ns made at each

st ep.

374

Aut onomous Mai nt enance Audi t Di agr am

Sel f - Audi t

Gr oup l eader s and member s

Sect i on Manager ’ s Audi t

Sect i on manager ( st af f , super vi sor s)

Top- Management Audi t

Di vi s i on manager , pr omot i on of f i ce di r ect or , pr omot i on

of f i ce st af f

At each st ep

Audi t ?

Gr oup act i v i t yr epor t

Audi t Appl i cat i onFor m

( Audi t sheet ) ①

Audi t ?

Audi t sheet ②

Audi t meet i ng Audi t Appl i cat i onFor m ② Pr omot i on Of f i ce

Audi t ?

Audi t sheet ③

Audi t meet i ng

PassI ssue “ pass”

st i cker f or st ep

Pl acest i cker on

equi p-ment

NO

YES

NO

YES

• Poi nt out pr obl ems

• Pr ovi de gui dance and suppor t

• Deci de r eadi ness f or t op-management audi t

• Deci de whet her gr oup has passed st ep

• Poi nt out pr obl ems

• Gi ve gui dance and advi ce NOGi ve expl anat i on and

gui dance

Coor di nat e schedul e

375

St ep 1. I ni t i al Cl eani ng

How t o det ect abnor mal i t i es

The st r uct ur e and f unct i on of t he equi pment i s t hor oughl y under st ood. Anomal y can be det ect ed cor r ect l y. Oper at or s have t hor ough t aggi ng ski l l s .

Level 3

Ser vi c i ng f or t he basi c condi t i ons

Cl eani ng, l ubr i cat i on and f ast eni ng ar e t hor oughl y done.

Level 2

I ni t i al c l eani ng

Wast e, dust and di r t ar e r emoved f r om t he mai n equi pment . The i nsi des of cover s and t he t anks ar e al so cl eaned.

Level 1

10% 30% 50% 70% 90%

(Outside Inside Processing point)

(Outside Inside Processing point)

(Tag on the outside Tag in the inside Tag on the processing point)

10% 30% 50% 70% 90%

10% 30% 50% 70% 90%

AM Criteria

376

Step 1. Initial Cleaning

Level 4

Measur es agai nst abnor mal i t i es

By t aki ng measur es agai nst abnor mal i t i es, r est or at i on and i mpr ovement abi l i t i es ar e cont i nuousl y r ai sed.

Level 5

Thor ough execut i on of i ni t i al c l eani ng

I ni t i al c l eani ng i s t hor oughl y execut ed and mai nt ai ned.

10% 30% 50% 70% 90%

(Outside Inside Processing point) 10% 30% 50% 70% 90%

(Tag on the outside Tag in the inside Tag on the processing point)

377

St ep 2. Count er measur es agai nst Di r t and Dust Sour ces / Di f f i cul t Ar eas t o Access

Level 1

Revel at i on of def ect i ve sour ces

The st at e of i ni t i al c l eani ng i s mai nt ai ned and di r t and dust sour ces and di f f i cul t ar eas t o access ar e cl ear l y shown.

Level 2

Count er measur es agai nst scat t er i ng

El i mi nat e t he sour ces of scat t er i ng r educe t he amount of di r t and dust l ocal i zed cover s and duct s ar e pl aced t o pr event scat t er i ng.

Level 3

Count er measur es agai nst di f f i cul t spot s t o car r y out i nspect i on

For t he spot s di f f i cul t t o car r y out i nspect i on, measur es ar e t aken such as r emovi ng LSs, r eveal i ng pr ocessi ng poi nt s or i nst al l i ng i nspect i on wi ndows.

10% 30% 50% 70% 90%

( I ni t i al c l eani ng Sour ces Det ect i on of di f f i cul t ar eas t o access)

( Reduce t he amount of di r t and dust Cover s Local i zed cover s)

(Investigation Improvement Easy inspection)

10% 30% 50% 70% 90%

10% 30% 50% 70% 90%

378

St ep 2. Count er measur es agai nst Di r t and Dust Sour ces / Di f f i cul t Ar eas t o Access

Level 4

Easy cl eani ng / i nspect i on

I mpr ovement s f or easy i nspect i on ar e made such as r emovi ng LSs, r eveal i ng pr ocessi ng poi nt s or i nst al l i ng i nspect i on wi ndows.

Level 5

I nspect i on dur i ng oper at i on / zer o scat t er i ng

Pr ocessi ng poi nt can be seen even dur i ng oper at i on. No scat t er i ng. Cover s can be r emoved by one- t ouch devi ce and cl eani ng and i nspect i on can be done easi l y.

10% 30% 50% 70% 90%

( Si mpl e cover I nspect i on dur i ng oper at i on No scat t er i ng) 10% 30% 50% 70% 90%

(Improvement Easy cleaning Easy inspection)

379

St ep 3. Pr epar at i on of Tempor ar y St andar ds of Aut onomous Mai nt enance

Revi ew t he t empor ar y st andar ds

By r epeat i ng t he i nspect i on based on t he t empor ar y st andar ds, some par t s of i nspect i on i t ems or per i ods needi ng amendment ar e r eveal ed.

Level 3

Make t empor ar y st andar ds

Cl eani ng / l ubr i cat i on / i nspect i on st andar ds whi ch can be i mpl ement ed wi t hi n t he l i mi t ed amount of t i me ar e pr epar ed.

Level 2

Knowl edge of t he f unct i onal st r uct ur e of t he machi neBased on t he condi t i on t hat c l eani ng and l ubr i cat i ng par t s, met hods, st andar ds and per i ods ar e t empor ar i l y det er mi ned and t hat st r uct ur e / f unct i on / pr i nci pl es of t he equi pment ar e under st ood, l ubr i cat i on and hydr aul i c syst em char t s ar e pr epar ed.

Level 1

10% 30% 50% 70% 90%

( Tempor ar y det er mi nat i on Funct i onal st r uct ur e Pr epar at i on of l ubr i cat i on,

hydr aul i c syst em char t s)

( Make t empor ar y st andar ds I nspect i on Det ect i on l oss due t o i nspect i on)

( I nspect i on I nt ensi ve i t ems Reveal t he i t ems t o be amended, Make amendment )

10% 30% 50% 70% 90%

10% 30% 50% 70% 90%

380

St ep 3. Pr epar at i on of Tempor ar y St andar ds of Aut onomous Mai nt enance

Level 4

Easy i nspect i on

Abnor mal i t i es can be f ound easi l y by usi ng vi sual cont r ol . Equi pment i s i mpr oved i n such a way as t o car r y out easy i nspect i on wi t hout bendi ng.

Level 5

St andar di zed, ef f i c i ent and ef f ect i ve i nspect i on

I nspect i on i t ems and i nspect i on per i ods ar e put t oget her . Ef f i c i ent and ef f ect i ve i nspect i on i s car r i ed out wi t hi n 10 mi n. / day ( St andar di zed / ef f i c i ent / ef f ect i ve i nspect i on) .

10% 30% 50% 70% 90%

(Within 30 min. Within 20 min. Within 10 min.) 10% 30% 50% 70% 90%

(Staring at Watch carefully At a glance)

381

St ep 4. Over al l I nspect i on

Level 1

I nspect i on based on t he t empor ar y st andar ds

Based on cl eani ng / l ubr i cat i on / i nspect i on st andar ds, t empor ar y i nspect i on st andar ds ar e made f or each over al l i nspect i on i t ems ( 6 i t ems) and mi nor def ect i ves ar e r eveal ed.

Level 2

Ski l l t r ai ni ng by super vi sor s and t eam l eader s

Super vi sor s and t eam l eader s make one- poi nt l essons f or each subj ect by whi ch t r ai ni ng i s car r i ed out t o oper at or s.

Level 3

Pr epar e st andar ds

Thr ough r evi ewi ng t empor ar y st andar ds, st andar ds ar e pr epar ed and mi nut e def ect i s r est or ed and i mpr oved.

10% 30% 50% 70% 90%

( I nspect i on Revi ew / Det er mi nat i on of st andar ds Revel at i on of def ect i ves)

( Make t r ai ni ng mat er i al s Educat i on & t r ai ni ng Hor i zont al expansi on)

( Pr epar at i on of st andar ds Rest or at i on I mpr ovement )

10% 30% 50% 70% 90%

10% 30% 50% 70% 90%

382

St ep 4. Over al l I nspect i on

Level 4

QA condi t i ons

Consi der i ng t he r el at i onshi p bet ween equi pment and qual i t y, t he opt i mal pr ocessi ng condi t i on i s det er mi ned ( Mai nt ai n t he cont r ol i t ems of manuf act ur i ng qual i t y and qual i t y st andar ds) .

Level 5

Smal l r epai r

Smal l r epai r s can be car r i ed out not by mai nt enance per sonnel but by oper at i on hi msel f .

10% 30% 50% 70% 90%

(Supervisors Leaders Operators) 10% 30% 50% 70% 90%

( I nvest i gat i on anal ysi s Opt i mal pr ocessi ng condi t i on Mai nt enance)

383

St ep 5. Aut onomous i nspect i on

Level 1

Revi ew of t he st andar ds

Cl eani ng / l ubr i cat i on / i nspect i on st andar ds ar e r evi ewed i n or der t o pr event t he r ecur r ence of br eakdowns / def ect i ves / mi nor st oppages / mi s- i nspect i ons.

Level 2

Dai l y i nspect i on

St andar ds ar e r evi ewed. Oper at or s check t hei r equi pment by t hei r 5 senses. Ther ef or e, anomal y can be det ect ed at an ear l y st age.

Level 3

Spar e par t s management

Exchange par t s / spar e par t s of t he equi pment ar e managed and t he concer ned peopl e have knowl edge and ski l l s on exchangi ng par t s and pr event i on of br eakdown.

10% 30% 50% 70% 90%

(Review Amendment Zero recurrence)

( Check by 5 senses Det ect abnor mal i t i es Count er measur es agai nst abnor mal i t i es)

(Management Skills Prevention)

10% 30% 50% 70% 90%

10% 30% 50% 70% 90%

384

St ep 5. Aut onomous i nspect i on

Level 4

Si mpl e di agnosi s

Oper at or s can est i mat e t he per i od of det er i or at i on l i mi t of t he equi pment and can det er mi ne t he det er i or at i on l i mi t f or each mode.

Level 5

Mai nt enance t r ai ni ng on pl anned mai nt enance

Ther e i s a scheme by whi ch oper at or s ar e t r ai ned t o i mpr ove t hei r mai nt enance ski l l s .

10% 30% 50% 70% 90%

(Supervisors Leaders Operators) 10% 30% 50% 70% 90%

(Estimate For each mode Establish the limit)

385

St ep 6. St andar di zat i on

Level 1

St andar di zat i on of j i gs and t ool s

Nor mal r epet i t i ve oper at i ons ar e st andar di zed and j i gs and t ool s ar e st andar di zed f or usage i n 5S act i v i t i es.

Level 2

St andar di zat i on of oper at i ons

Mur i ( unnat ur al oper at i on) , Mur a ( i r r egul ar oper at i on) , Muda ( non val ue added oper at i on) ar e gr asped among movement s i n t he oper at i on, anal yzed, i mpr oved, and oper at i ons ar e st andar di zed.

Level 3

I mpr ovement ski l l s

I mpr ovement act i v i t i es ar e pr act i ced at t he shop and i mpr ovement ski l l s ar e cont i nuousl y r ai sed.

10% 30% 50% 70% 90%

(5S 3 normal operations Standardization)

(Analysis Improvement Standardization)

( Tr ai ni ng of I mpr ovement I mpr ovement ski l l s i mpr ovement ski l l s act i v i t i es ar e r ai sed)

10% 30% 50% 70% 90%

10% 30% 50% 70% 90%

386

St ep 6. St andar di zat i on

Level 4

Saf et y cont r ol

Zer o br eakdown, zer o def ect i ve, zer o mi nor st oppage and zer o acci dent ar e act ual i zed.

Level 5

Shop management

Ther e i s a scheme by whi ch r educt i on of l osses and mai nt enance cost r educt i on ar e cont i nuousl y i n pr ogr ess.

10% 30% 50% 70% 90%

( Gr asp l osses Reduce cost Cont i nuous i mpr ovement ) 10% 30% 50% 70% 90%

(Zero accident Zero injury Zero near-misses)

387

St ep 7. Thor ough aut onomous management

Level 1

Act i v i t y boar d

Pol i c i es ar e managed by t he act i v i t y boar d and pol i c i es, r esul t s, pr obl ems and t hemes ar e cl ar i f i ed showi ng cont ent s of act i v i t i es.

Level 2

Gr oup meet i ng

The t r ends of br eakdown l osses, def ect i ve l osses and mi nor st oppage l osses ar e anal yzed and t he i mpr ovement pl ans ar e di scussed at gr oup meet i ngs.

Level 3

I ndi v i dual i mpr ovement

The r esul t s and pr obl ems of manuf act ur i ng gr oups ar e known and f ocused i mpr ovement ( PPA, I E met hods, et c. ) i s car r i ed out act i vel y.

10% 30% 50% 70% 90%

(Notice board Activity board Utilization board)

( Cl ar i f i cat i on of pr obl ems Meet i ng I mpr ovement )

( Cl ar i f i cat i on of pr obl ems Count er measur es Zer o r ecur r ence)

10% 30% 50% 70% 90%

10% 30% 50% 70% 90%

388

St ep 7. Thor ough aut onomous management

Level 4

Common use of i nf or mat i on

Common use of i nf or mat i on i s car r i ed out at i mpr ovement case st udy meet i ngs and / or gr oup wor kshops. I mpr ovement abi l i t y at t he wor kshop i s i mpr oved.

Level 5

Mai nt enance car r i ed out mai nl y by oper at or s

Oper at or s can t ake car e of mai nt enance act i v i t i es agai nst def ect i ves and br eakdowns, such as r est or i ng and i mpr ovement act i v i t i es. Speci al mai nt enance per sonnel ar e engaged i n devel opi ng mor e advanced mai nt enance .

10% 30% 50% 70% 90%

( Smal l r epai r Mai nt enance t r ai ni ng Mai nt enance) 10% 30% 50% 70% 90%

( St udy meet i ngs Common use of i nf or mat i on Hor i zont al expansi on)

389

TABLE

Step 1 Autonomous Maintenance Audit Sheets Sheet 1 of 5

No. Audit points Results

1. 1.11.21.31.41.5

1.6

1.71.81.9

1.10

Group activity (General) Are aims of Step 1 understood adequately?Is activity plan made in advance? Well executed?Are managers’ models well understood?Is activity board adequately utilized?Are defective areas accurately located? Confirmed by all members?Are previously overlooked defective areas detectable with current knowledge?Are identification tags collected and kept after remedies?Are questions sufficiently posed?Are questions definitely resolved? Understood by all members?Are sources of contamination accurately located? Written onto source of contamination list?

TABLE Step 1: Initial Cleaning

390


1.111.121.131.141.151.16

1.171.18

1.191.20

Is up/downtime work clearly distinguished?Are safety matters carefully respected?Are TPM activity hours and frequency adequate?Is more efficient way of TPM activity pursued?Are used spare parts and consumables recorded?Is meeting after on-site activity definitely held? Reports submitted?Is activity participated in by all members?Are all members cooperating equally? Not led by particular member?Are noteworthy ideas introduced actively to other PM groups?Is cooperation with full-time maintenance satisfactory?

(-Continued)TABLE Step 1: Initial Cleaning

391


22.1

(1)(2)(3)(4)(5)(6)

(7)

(8)

Equipment (Main body and surroundings)No contamination or foreign materials at locations as listed below?Rotating, reciprocating or positioning partsParts contacting workpiecesFrames, beds or any other memberConveyors, chutes or any other material transfer facilitiesTools, jigs or any other auxiliary devicesSensors, microswitches, instruments, lighting(exterior/interior) of consoles/panelsAir filters, regulators, lubricators, cylinders, solenoid valves or other pneumatic devicesMotors, belts or safety covers and surroundings


392


2.2(1)(2)(3)(4)

2.3

2.4

2.52.6

2.72.82.9

No deteriorated or defective parts as listed below?Loose, damaged or missing nuts/boltsLooseness in sliding parts, fixtures of tools or jigsAbnormal noise in motors, solenoid valves, etc.Damaged pipes, hoses or cablesAre tools and jigs stored at designated locations? No shortage or damage?No nuts, bolts, tools, workpieces or any other unnecessary materials in and around equipment? No dropped parts on floor?No unnecessary pieces of equipment?Can quality/defective products or scraps be clearly distinguished?Are labels and name plates clean and legible?Do status display and warning lamps function properly?Do safety devices function properly?


393


3.3.1

3.23.33.44.4.15.5.1

LubricationNo dirt, dust or leakage in and around air lubricators, oil reservoirs or centralized systems?Is oil level proper? Adequate lubricants at lubricating surfaces?No contamination at lubricating points and surfaces?Are lubricants not contaminated? Not deteriorated?Short remedial programIs outline of short remedial program known?Residual issuesNo residual questions, equipment defects? If so, do reasonable explanations exist? Are plans and schedules to solve these issues clear?


394



1. 1.11.222.12.22.32.42.5

2.6

2.72.82.9

Step 1 conditionsIs cleanliness attained in Step 1 well maintained?Are residual issues left over from Step 1 resolved?Group activity (General)Are aims of Step 2 understood adequately?Is activity plan made in advance? Well executed?Are managers’ models well understood?Is activity board adequately utilized?Are defective areas accurately located? Confirmed by all members?No overlooked defective areas detectable with current knowledge?Are identification tags collected and kept after remedies?Are questions sufficiently posed?Are questions definitely resolved? Understood by all members?

TABLE Step 2: Countermeasures to Sources of Contamination

395

(-Continued)


2.10(1)(2)(3)(4)

2.112.122.132.142.15

2.162.17

2.182.19

Is activity developed in following priority?Remove generation of contaminants at source.Prevent contaminants from dispersing.Improve cleaning methods and tools.Modify equipment to make cleaning tasks easier.Are safety matters carefully respected?Are TPM activity hours and frequency adequate?Is more efficient way of TPM activity pursued?Are used spare parts and consumable recorded?Is meeting after on-site activity definitely held? Reports submitted?Is activity participated in by all members?Are all members cooperating equally? Not led by particular member?Are noteworthy ideas introduced actively to other PM groups?Is cooperation with full-time maintenance satisfactory?

TABLE Step 2: Countermeasures to Sources of Contamination

396


3.3.1

3.23.3

3.4

3.5

3.6

Tentative cleaning standardsAre cleaning time targets, work allocation and areas clearly specified by manager? Are these prescriptions well understood?Are tentative cleaning standards set at the beginning of Step 2?Are cleaning intervals identified to maintain cleanliness achieved in Step 1?Are tentative cleaning standards revised as every remedial action is taken?Is cleaning work to be done during up/downtime of equipment clearly distinguished? Well understood?Can everyone clean equipment in accordance with cleaning standards? Time targets achieved? If not, are adequate plans and schedules prepared?

(-Continued)TABLE Step 2: Countermeasures to Sources of Contamination

397


4.4.1

4.2

4.3

4.4

4.5

5.5.1

5.2

5.3

Sources of contaminationAre remedial actions taken deliberately, based on detailed assessment of actual generating conditions of contaminants? Are locations and manners of contaminants clearly recognized by detailed observation? Where-where analysis conducted, if necessary?Are structure and function of equipment sufficiently learned? Why-why analysis conducted, if necessary?Are all simple sources resulting from deteriorated parts such as water, oil and stream leakage remedied?Are cost and effects of remedies reviewed? Actual figures recorded?Difficult cleaning areaAre remedial actions taken deliberately, based on detailed assessment of actual conditions of cleaning tasks in awkward work areas?Are sources thoroughly remedied to make actions against difficult cleaning areas unnecessary?Are costs and effects of remedies reviewed? Actual figures recorded?


398


6.6.1

6.26.3

6.4

6.56.67.7.1

7.27.3

Equipment (Main body and surroundings)Are tools and jigs stored at designated locations? No shortage or damage?No unnecessary pieces of equipment?No unnecessary materials in process? No dropped parts on floor?Can quality/defective products or scraps be clearly distinguished?Do status display and warning lamps function properly?Do safety devices function properly?LubricationNo dirt, dust or leakage in and around air lubricators, oil reservoirs or centralized systems?Is oil level proper? Adequate lubricants at lubricating surfaces?Are lubricants not contaminated? Not deteriorated?


399


8.8.18.2

9.9.19.29.39.4

9.5

10.10.1

10.2

Visual controlAre visual controls devised to facilitate cleaning tasks?Are available visual controls installed using current technical knowledge and skill?Short remedial programIs subject selected from the six big losses?Are problems clearly identified? Targets pinpointed?No easy countermeasures taken?Are cost and effects of program reviewed? Actual figures recorded?Are preventive measures against recurrence of problems provided?Residual issuesNo residual questions, equipment defects? Are secure plans and schedules for corrective actions prepared?No residual remedies against sources of contamination and difficult cleaning areas? If so, do reasonable explanations exist? Are plans and schedules to solve these issues clear?


400



1. 1.1

1.222.12.22.32.42.52.62.72.8

Step 2 conditionsIs cleanliness attained in Step 2 well maintained?Cleaning standards definitely observed?Are residual issues left over from Step 2 resolved?Group activity (General)Are aims of Step 3 understood adequately?Is activity plan made in advance? Well executed?Are managers’ models well understood?Is TPM activity board adequately utilized?Are safety matters carefully respected?Are TPM activity hours and frequency adequate?Is more efficient way of TPM activity pursued?Are used spare parts and consumables recorded?

TABLE Step 3: Cleaning and Lubricating Standards

401



2.9

2.10

2.11

2.122.133.3.1

3.2

3.3

Is meeting after on-site activity definitely held? Reports submitted?Is activity participated in by all members? No indication of dropout?Are all members cooperating equally? Not led by particular member?Are noteworthy ideas introduced actively to other PM groups?Is cooperation with full-time maintenance satisfactory?Education (Lubrication)Is education for group leaders and operators conducted?More than 80% of subject matter comprehended?Are lubrication-related devices, parts type, name, structure and function understood?Are phenomena, causes, criteria, evaluation and remedies of lubrication-related equipment defects recognized?Can everyone actually inspect equipment?

(-Continued)TABLE Step 3: Cleaning and Lubricating Standards

402



3.4

(1)(2)(3)(4)4.4.14.24.3

4.4

4.5

4.6

Does everyone know matters in terms of equipment for which they are responsible as listed here:Lubricating points and surfaces.Type of lubricants to be applied.Inspection and lubrication intervals.Check points.Overall inspection (Lubrication)Are all lubricating points and surfaces definitely located?Adequate lubricants at lubricating surfaces?No wear, overheating, abnormal noise or odor at lubricating surfaces?No contaminated, leaked, damaged or clogged grease cups, nipples or any other lubricating points?No pipes, valves and fittings in remote or centralized systems kept in above conditions?Are lubricants not contaminated? Not deteriorated?


403



5.5.1

5.2

5.3

5.4

5.5

Tentative lubricating standardsAre lubricating time targets, work allocation and areas clearly specified by manager? Are these prescriptions well understood?Are tentative lubricating standards set immediately after overall inspection?Are tentative lubricating standards revised after every remedial action?Is lubricating work to be done during up/downtime of equipment clearly distinguished? Well understood?Can everyone inspect and lubricate equipment in accordance with tentative lubrication standards? Time targets achieved? If not, are adequate plans and schedules prepared?


404



6.6.1

6.2

6.3

7.7.1

7.27.3

Cleaning/lubricating standardsAre cleaning/lubricating standards comprised of systematic combinations of tentative cleaning standards set in Step 2 and lubricating standards set in Step 3?Can everyone locate any defects relating to basic equipment conditions?Can everyone clean and lubricate in accordance with standards? Time target achieved? If not, are adequate plans and schedules prepared?Equipment (Main body and surroundings)Are tools and jigs stored at designated locations? No shortage or damage?No unnecessary pieces or equipment?No unnecessary materials in process? No dropped parts on floor?


405



7.4

7.57.688.1

8.2

9.9.19.2

Can quality, defective products or scraps be clearly distinguished?Do status display and warning lamps function properly?Do safety devices function properly?Visual controlAre color lubrication control and visual controls such as lubrication labels, instructions for oil levels or adequate ranges of instruments thoroughly applied?Are new visual controls devised? Noteworthy ideas actively revealed to other PM groups?Short remedial programIs subject selected from the six big loses?Are problems clearly identified? Targets pinpointed?


406



9.39.4

9.5

10.10.1

10.2

No easy countermeasures taken?Are cost and effects of program reviewed? Actual figures recorded?Are preventive measures against recurrence of problems provided?Residual issuesNo residual questions, equipment defects? Are secure plans and schedules for corrective actions prepared?No residual remedies against difficult lubricating areas? If so, do reasonable explanations exist? Are plans and schedules to solve these issues clear?


407



1. 1.1

1.2

22.12.22.32.42.52.62.72.8

Step 3 conditionsAre the basic equipment conditions attained in Step 3 well maintained? Cleaning/lubricating standards definitely observed?Are residual issues left over from Step 2 or previous sub step resolved?Group activity (General)Are aims of Step 4 understood adequately?Is activity plan made in advance? Well executed?Are managers’ models well understood?Is activity board adequately utilized?Are safety matters carefully respected?Are TPM activity hours and frequency adequate?Is more efficient way of TPM activity pursued?Are used spare parts and consumables recorded?

TABLE Step 4: Overall Inspection

408



2.9

2.10

2.11

2.122.133.3.1

3.2

3.3

Is meeting after on-site activity definitely held? Reports submitted?Is activity participated in by all members? No indication of dropout?Are all members cooperating equally? Not led by particular member?Are noteworthy ideas introduced actively to other PM groups?Is cooperation with full-time maintenance satisfactory?Inspection education (By each category)Is education for group leaders and operators conducted?More than 80% of subject matter comprehended?Are parts type, name, structure and function of equipment understood?Are phenomena, causes, criteria, evaluation and remedies of equipment defects understood? Can everyone actually inspect equipment?

(-Continued)TABLE Step 4: Overall Inspection

409



3.4

4.

5.5.1

5.2

5.35.4

5.5

Does everyone know relevant inspecting items and check points in equipment for which they are responsible?Overall inspection (By each category)　 Use attached sheets for each inspection category.Tentative inspecting standards (By each category)Are inspecting time targets, 　 work allocation and areas clearly specified by manager? Are these prescriptions well understood?Are tentative inspecting standards set immediately after overall inspection?Are inspecting standards revised after every remedial action?Is inspecting to be done during up/downtime of equipment clearly distinguished? Well understood?Can everyone conduct routine inspection in accordance with tentative inspecting standards? Can defective parts actually be discovered?


410



5.65.7

6.6.1

6.26.3

6.4

6.56.6

Are inspecting intervals estimated?Are time targets achieved? If not, are adequate plans and schedules prepared?Equipment (Main body and surroundings)Are tools and jigs stored at designated locations? No shortage or damage?No unnecessary pieces or equipment?No unnecessary materials in process? No dropped parts on floor?Can quality/defective products or scraps be clearly distinguished?Do status display and warning lamps function properly?Do safety devices function properly?


411



7.7.1

7.2

8.8.18.28.38.4

8.5

Visual controlAre visual controls thoroughly applied to facilitate inspecting tasks?Are new visual controls devised? Noteworthy ideas actively revealed to other PM groups?Short remedial programIs subject selected from the six big loses?Are problems clearly identified? Targets pinpointed?No easy countermeasures taken?Are cost and effects of program reviewed? Actual figures recorded?Are preventive measures against recurrence of problems provided?


412



9.9.1

9.2

Residual issuesNo residual questions, equipment defects? Are secure plans and schedules for corrective actions prepared?No residual remedies against difficult inspecting areas? If so, do reasonable explanations exist? Are plans and schedules to solve these issues clear?


413



4.4.1

4.24.3

4.44.54.6

Step 4-1 (Overall fastener inspection)No corroded, loose or bent nuts and bolts? Minimum two threads exposed? No damaged threads?Are lengths of bolts adequate?Are looseness prevention methods such as washers properly used?Are double nuts or match marks used for critical bolts?Are other fastener-related parts inspected?Are all discovered defective parts corrected?


414



4.4.1

4.24.3

4.4

4.5

Step 4-2 (Overall electrical inspection)No contamination, scratched, bent or loose connections at cables and conduit pipes? None touching water, steam or moving items? No threat to safety?No disconnections or breakages in ground wires?Do instruments installed on consoles, control panels or distribution boards function properly? No burned out lamps? Are switches easy to use? No possibility of operation mistakes? Are visual controls properly applied?No dirt, dust or any other contamination in/outside consoles, control panels and distribution boards? Are wirings neat? No unnecessary materials left in boxes? Sufficient ventilation?Do motors produce no abnormal heat, noise or order? No loose setting bolts? Is lubrication satisfactory?


415



4.6

4.7

4.84.4.1

4.2

4.3

4.44.5

4.64.7

No contaminated or damaged limit, proximity switches or any other sensors? No improper actuations?Are all electrical and instrumental parts, devices, wiring, or conduit pipes inspected?Are all discovered defective parts corrected?Step 4-3 (Overall power transmission inspection)No deteriorated or oil contaminated belts? Are belt tensions proper? No worn or misaligned pulleys?No wear or slack in chains or sprockets? No oily contamination around chains?No damage, misalignment, loose fixtures or play in shaft? No overheating, vibration or noise at bearings?No noise, vibration or overheating at gears, breaks?Are critical areas visible through safety cover? Are covers adequately modified?Are all power transmission parts and devices inspected?Are all discovered defective parts corrected?


416



4.4.1

4.2

4.3

4.4

4.54.64.7

Step 4-4 (Overall hydraulic/pneumatic inspection)No contamination, damage, leakage or vibration in hydraulic and pneumatic equipment, pipes, hoses, valves, fittings or any other parts?No abnormal noise, vibration or overheating in rotary machinery, motors, solenoid and selector vales, or any other hydraulic and pneumatic parts?Are air filters, regulators and lubricators properly installed? Easy to inspect for oil quantity? Oil levels satisfactory? No foreign particle in filters? Condensed water drained?Are pressure gauges, thermometers, level gauges properly installed? Easy to inspect? Actuating normally?Are tubes, pipes and hoses properly installed?Are all other hydraulic/pneumatic parts and devices inspected?Are all discovered defective parts corrected?


417



1. 1.1

1.21.3

1.4

1.52.2.12.22.32.42.5

Step 1 through 4 reviewAre equipment detected from Step 1 through 4 definitely corrected?Are remedial actions to sources of contamination completed?Are difficult areas for conducting routine maintenance adequately modified?No residual issues in above? If so, do reasonable explanations exist? Are plans and schedules to solve these issues clear?No unanswered questions?Group activity (General) Are aims of Step 5 understood adequately?Is activity plan made in advance? Well executed?Are managers’ models well understood?Is activity board adequately utilized?Are safety matters carefully respected?

TABLE Step 5: Autonomous Maintenance standards

418



2.62.72.82.9

2.10

2.11

2.122.133.3.1

Are TPM activity hours and frequency adequate?Is more efficient way of TPM activity pursued?Are used spare parts and consumables recorded?Is meeting after on-site activity definitely held? Reports submitted?Is activity participated in by all members? No indication of dropout?Are all members cooperating equally? Not led by particular member?Are noteworthy ideas introduced actively to other PM groups?Is cooperation with full-time maintenance satisfactory?Routine maintenance activityAre cleaning, lubricating and inspecting times sufficiently reduced? Are relevant standards faithfully revised whenever work methods or equipment are modified?

(-Continued)TABLE Step 5: Autonomous Maintenance standards

419



3.2

3.3

3.4

3.5

3.6

Are breakdowns caused by internal deterioration prevented with the five senses? Is warning card system effectively operated?Are countermeasures against misoperation taken in cooperation with full-time maintenance?Are remarkable causes of breakdowns and misoperation prevention actively taught to all PM groups? Are related standards always reviewed?Are standards prepared in the past steps sufficiently assessed in terms of safety, quality and breakdowns? Are discovered problems remedied?Are tentative inspecting standards set in Step 4 thoroughly reviewed by making a detailed comparison with those prepared by full-time maintenance? Is allocation of inspecting tasks between autonomous and full-time maintenance adequate?


420



3.7

3.8

3.9

3.10

4.4.1

4.24.3

Are autonomous maintenance standards, by systematically combining various standards, set in the past steps?Are maintenance schedules prepared to definitely conduct operator’s routine maintenance? Faithfully executed?Is routine maintenance work to be done during up/downtime of equipment clearly distinguished? Well understood?Can everyone clean, lubricate and inspect equipment in accordance with autonomous maintenance standards? Time targets achieved? If not, are adequate plans and schedules prepared?Equipment (Main body and surroundings)Are tools and jigs stored at designated locations? No shortage or damage?No unnecessary pieces of equipment?No unnecessary materials in process? No dropped parts on floor?


421



4.4

4.54.65.5.1

5.2

6.6.16.26.36.46.5

Can quality/defective products or scraps be clearly distinguished?Do status display and warning lamps function properly?Do safety devices function properly?Visual controlAre visual controls thoroughly applied to facilitate inspecting tasks?Are new visual controls devised? Noteworthy ideas actively revealed to other PM groups?Short remedial programIs subject selected from the six big losses?Are matters of quality being dealt with?Are problems clearly identified? Targets pinpointed?No easy countermeasures taken?Are cost and effects of program reviewed? Actual figures recorded?


422



6.6

7.7.1

Are preventive measures against recurrence of problems provided?Residual issuesNo residual equipment related issues? If so, do reasonable explanations exist? Are plans and schedules to solve these issues clear? Is adequate assistance of full-time maintenance arranged?


423

TABLE



1. 1.1

1.2

1.3

2.2.12.22.32.42.5

Step 5 conditionAre all equipment-related problems solved? No residual issues?Is operators’ routine maintenance definitely executed in accordance with autonomous maintenance standards and schedules?Are cause analysis and preventive measures taken in each event of breakdowns or minor stoppages occurring in spite of secure observation of autonomous maintenance standards? Assistance of full-time maintenance satisfactory?Group activity (General) Are aims of Step 6 understood adequately?Is activity plan made in advance? Well executed?Are managers’ models well understood?Is activity board adequately utilized?Are safety matters carefully respected?

TABLE Step 6: Process Quality Assurance

424



2.62.72.82.9

2.10

2.11

2.122.133.

4.4.1

Are TPM activity hours and frequency adequate?Is more efficient way of TPM activity pursued?Are used spare parts and consumables recorded?Is meeting after on-site activity definitely held? Reports submitted?Is activity participated in by all members? No indication of dropout?Are all members cooperating equally? Not led by particular member?Are noteworthy ideas introduced actively to other PM groups?Is cooperation with full-time maintenance satisfactory?Sub step activities　 Use attached sheets.Equipment (Main body and surroundings)Do status display and warning lamps function properly?

(-Continued)TABLE Step 6: Process Quality Assurance

425



4.25.5.1

6.6.16.26.36.4

6.5

Do safety devices function properly?Visual controlAre new visual controls devised? Noteworthy ideas actively revealed to other PM groups?Short remedial programIs subject selected from the six big loses?Are problems clearly identified? Targets pinpointed?No easy countermeasures taken?Are cost and effects of program reviewed? Actual figures recorded?Are preventive measures against recurrence of problems provided?


426



3.3.1

3.2

3.3

3.4

(1) (2) (3)

Step 6-1-1Are process quality and tolerances clearly identified at each exit of equipment? Quality assurance flow diagram(QAFD) drawn?Are process quality assurance lists prepared by reviewing quality-related modifications carried out in the past steps in terms of equipment, work methods, quality control standards, visual controls and mistake proofs?Are quality assurance flow diagrams revised whenever quality related modifications of equipment or work methods take place?Process quality and relevant inspecting items in terms of initial, interim and final product:Clearly defined? Absolutely needed?Well understood?Easy to understand?


427



3.3.1

(1) (2) (3)3.2

3.3

Step 6-1-2Quality standards, inspecting items and criteria, and corrective actions to be taken when problems occur in terms of initial, interim and final product:Well observed?Easy to understood?Can deviation be detected at a glance when problems occur?Can everyone accurately and promptly inform relevant departments when quality defects occur?Are quality standards, inspecting item and criteria corrective actions, visual controls and mistake proofs sufficiently improved?


428



3.4

3.3.1

3.2

(1) (2) (3) (4) (5)

Are all quality-related documents revised after any kind of modification?Step 6-1-3Are past outflows of defective products accurately classified in accordance with given criteria?Preventive measures against outflows of defective product and inspecting items:Clearly defined? Absolutely needed?Well understood?Well observed?Easy to observe?Can outflows of defective products be detected at a glance when they occur?


429



3.3

3.4

3.5

3.3.1

3.2 (1) (2) (3) (4) (5)

Can everyone accurately and promptly inform relevant departments when defective products flow out?Are preventive measures against outflows of defective product and inspecting items sufficiently improved?Are all quality related documents revised after any kind of modification?Step 6-1-4Are handling procedures for defective or quality products carefully assessed?Handling procedures for defective or quality products:Clearly defined? Well understood?Well observed?Easy to observe?Can deviation be detected at a glance when products are handled improperly?


430



3.3

3.4

3.5

3.3.1

3.2

3.3

3.4

Can everyone accurately and promptly inform relevant departments when products are handled improperly?Are handling procedures for defective or quality products and inspecting items sufficiently improved?Are all quality related documents revised after any kind of modification?Step 6-1-5Is process automatically shut down whenever quality defects occur?Is alarm message or display issued whenever quality defects occur?Can everyone immediately detect when defective product is manufactured?Are mistake proofs, alarm displays and visual controls completely installed and improved further?


431

6. Three key points for successful small group activities

Action board

Meeting → meeting report of the small group activity

One point lessonThree itemsthe basic knowledge

case study of troubles

case study of improvement

432

It shows the history of the activities very well.

This is the real activity bulletin board.

The activity bulletin board is your face !your heart !your power !

433

7. Roles of operators and maintenance people

434

Roles of operators and maintenance people

Target MethodsActivities Allocation

Prevent Deterioration

Measure Deterioration

Restore Equipment Operators Maintenance


Normal operation

Daily maintenance

Periodic maintenance

Proper operation

Setup/adjustment

Cleaning・Detecting and correcting hidden faults

Lubrication

Tightening bolts and nuts

Conditions of use, daily deterioration check

Minor servicing

Periodic inspection

Periodic testing

Periodic servicing

○

○

○

○

○

○

○

○

○

○

○

435

Figure Classification and Allocation of Maintenance Tasks

Overall equipment effectiveness at

least 85%

Improvement activities

Improvement activities

Breakdown maintenance

Improving reliability

Improving maintainability

Trend testing

Non-routine servicing

Rapid discovery of abnormalities, prompt and accurate reporting

Repair breakdowns

Strengthen

Reduce load

Increase precision

Develop condition monitoring

Improve testing procedures

Improve servicing procedures

Improve servicing quality ○

○

○

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○

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436

Appendix ３ Examples of One Point Lessons

437

One-Point LessonTheme: V-belt

1. Basic Knowledge

2. Problem Case Study

3. Improvement Case Study

(check one)

X

1. Do not use V- bel t when i t t ouches t he base

2. Do not i gnor e ver t i cal shaki ng of V- bel t

The V- bel t i s dr i ven by t he t r ansmi ssi on of t he wedge t hat cut s i nt o t he si de of t he V-pul l ey. When t he V- bel t t ouches t he sur f ace, t he ef f ect of t he wedge i s l ost and sl i ppi ng occur s

Adj ust t ensi on and cent er of pul l ey

Yar dst i ck f or r el at i onshi p bet ween t ensi on and heat

Written by: Reference #Location:

Date: Revision Date

ver t i cal shaki ng i s caused by-cent er f r i ct i on-l ooseni ng-f r i c t i on

438

One-Point Lesson 1. Basic Knowledge



(check one)

X


Date: Revision Date

Theme: Ai r Cl ut ch: St r uct ur ed Di agr am and Oper at i on

Thi s dr y s i ngl e- pl at e ( f r i ct i on) t ype cl ut ch conver t s el ect r omagnet i c f or ce i nt o pneumat i c pr essur e and i s consi der abl y heavi er t han an el ect r omagnet i c c l ut ch.

Oper at i on• The f l ywheel ( 13 i s a V- pul l ey

whi ch r ot at es al ong wi t h t he cl ut ch di sk ( 1) .

• At t ached t o t he cl ut ch housi ng ( 10) secur ed t o t he f l ywheel ar e a pr essur e di sk ( 4) [ suppor t ed by a gui de key ( 3) ] , a di aphr agm ( 6) and a r ot ar y connect i on ( 9) , et c.

• When t he ON but t on i s pushed, ai r swi t ched by an el ect r omagnet i c val ve ent er s t he di aphr agm ( 6) t hr ough t he r ot ar y connect i on ( 9) , swel l i ng t he di aphr agm and pr essi ng agai nst a c l ut ch di sk ( 1) suppor t ed by a dr i ve shaf t ( 11) and f r i ct i on al ong t he cl ut ch f aci ng ( 2) t r ansmi t s r ot at i onal f or ce t o t he dr i ve shaf t and br i ngs down t he sl i de.

• When t he sl i de r eaches t he upper dead poi nt , t he ai r shut s of f and escapes f r om t he di aphr agm. A r et ur n spr i ng causes t he pr essur e di sk t o r et ur n and t he br ake i s r el eased.

439




(check one)

X


Date: Revision Date

Theme: Ai r Cl ut ch: Fai l ur es and Mal f unct i ons I nspect i on Poi nt s

Phenomenon Cause Measur es1. Sl ow dr i ve

shaf t r ot at i on ( s l i ppi ng)

1. Wor n scr at ched br ake f aci ng

2. Dr op i n ai r pr essur e

1. Repl ace l i ni ng

2. I nvent or y and r epai r ai r l eaks

2. Rot at i on not t r ansmi t t ed

1. No ai r comi ng

2. Br oken di aphr agm

1. I nvent or y and r epai r el ect r i cal f ai l ur es

2. Repl ace3. Odd noi ses 1. Bear i ngs out

of oi l , wor n or damaged

2. Spl i ne wear

3. Loose mount i ng bol t s

1. Check oi l ; r epl ace

2. Repai r or r epl ace

3. Ti ght en, st op

4. Vi br at i on 1. Wor n or damaged bear i ngs

2. Spl i ne wear

3. Loose mount i ng bol t s

1. Repl ace

2. Repai r or r epl ace

3. Ti ght en, st op

5. Heat 1. Di sk s l i ppage

2. Bear i ng wear

1. Adj ust or r epl ace

2. Repl ace6. Br ake sl i ppage 1. Def or med or

br oken spr i ng1. Repl ace

I mpor t ant I nspect i on Poi nt s

1. Any unusual noi ses, v i br at i on, heat ?

2. No wobbl e i n r ot at i on?

3. I s f r i ct i on agai nst f aci ng appr opr i at e? - - check st r oke

4. Ar e al l mount i ng bol t s appr opr i at el y t i ght ? - - appl y/ check r egi st r at i on mar ks

5. Any ai r l eaks i n t he r ot ar y connect i on?

440




(check one)

X


Date: Revision Date

Theme: How t o Mar k Nut s and Bol t s

Don’ t t ouch bol t s wi t h RED pai nt - - onl y mai nt enance checks/ t i ght ens

Put dot on t op of bol t , l i ke t hi s:

Bol t s checked dur i ng i nspect i on - - add whi t e mat ch mar ks af t er bol t pr oper l y secur ed

Mat ch mar ks shoul d cover t op, s i de and bot t om l i ke t hi s:

441




(check one)

X


Date: Revision Date

Theme: Pneumat i c Devi ces: Ai r Fi l t er

St r uct ur al Di agr am Basi c Funct i ons➊Pr ovi des cl ean dr y ai r , f r ee

of moi st ur e, oi l and dust➋Pr ovi des Cent r i f ugat i on,

separ at i on and dust r emoval f unct i ons f or use i n pneumat i c aut omat i c cont r ol c i r cui t s

➌Def l ect or s spi n compr essed ai r ent er i ng at I N; as condensat e and cont ami nant s ar e cent r i f uged t o t he i nner wal l , t hey col l ect i n t he bowl

Funct i ons of I ndi v i dual Par t s

1. Def l ect orI mpar t s cent r i f ugal f or ce t o compr essed

ai r

2. Fi l t er el ementRemoves mi cr oscopi c par t i c l es f r om

compr essed ai r

3. Baf f l e pl at ePr event s backf l ow of condensat e and

cont ami nant s4. Dr ai n val ve Al l ows r emoval of condensat e, et c.

5. Et c.

442




(check one)

X


Date: Revision Date

Theme: Ai r Fi l t er : Fai l ur es and Mal f unct i ons

Phenomenon Cause Measur es1. Cont ami nant s come

out of OUT por t1- 1 Negl ect ed

cont ami nant r emoval

1- 1 Remove cont ami nant s r egul ar l y each shi f t

1- 2 Fl ow t hr ough f i l t er exceeds pr escr i bed vol ume

1- 2 Use appr opr i at e f l ow/ f i l t er

2. Ext er nal ai r l eak 2- 1 Poor O- r i ng ( 5) seal

2- 1 Repl ace O- r i ng

2- 2 Bad dr ai n val ve ( 9)

2- 2 Repai r or r epl ace

3. Excessi ve dr op i n pr essur e

3- 1 Fi l t er el ement ( 2) c l ogged

3- 1 Cl ean or r epl ace

3- 2 I mper f ect el ement ( 2) seal

3- 2 Repl ace wi t h l ar ger one

4. For ei gn mat t er comes out of OUT por t

4- 1 Damaged f i l t er el ement

4- 1 Repl ace f i l t er el ement

4- 2 I mper f ect seal el ement

4- 2- 1 Repl ace seal ant

4- 2- 2 Repai r or t i ght en el ement hol der

5. Damaged bowl 5- 1 Used i n at mospher e cont ai ni ng an or gani c sol vent such as t ol uene or t hi nner

5- 1 Use met al bowl

443




(check one)

X


Date: Revision Date

Theme: Fi l t er

Fi l t er

Fi l t er OKI ndi cat or down

Fi l t er Cl oggedI ndi cat or i n up posi t i on

444




(check one)

X


Date: Revision Date

Theme: Your Tool s and How t o Use Them

St r uct ur eBasi c

Funct i onsPr oper

Handl i ngHand Oi l er Nozzl e- capped

pol yet hyl ene cont ai ner

Oi l can

Pump oi l can

Al l used f or hand oi l i ng

Used wi t h l ow vi scosi t y oi l

Pl ace t i p of nozzl e f aci ng down at oi l i ng si t e and pr ess l i ght l y on cont ai ner

Do not cr ush t i p

Keep cl ean and cl ear of di r t and dust

Desi gnat e and use speci f i c cont ai ner s f or di f f er ent t ypes of oi l

Ot her exampl es:• Oi l can• Funnel• Pi st ol - t ype oi l er• Lever - t ype gr ease gun• Aut omat i c gr ease syst ems, et c.

445




(check one)

X


Date: Revision Date

Theme: I mpr ovement of Unr eadabl e Oi l Level Gauge on Br ake

Current SituationThe oi l gauges on a conveyor br ake and a gear mot or

l can’ t be checked because t hey ar e hi dden behi nd pul l eys

l ar e di scol or ed and cl oudySpar es ar e di f f i cul t t o get and har d t o i nst al l , so t he gauges ar en’ t checked and l ubr i cat i on i s l ef t unmanaged.

Description of ImprovementWe at t ached a commer ci al l y avai l abl e oi l gauge t o a shor t pi pe i nser t ed i n t he dr ai n hol e. Thi s made i t easy t o check t he oi l l evel .

Key Points to Note1. Don’ t at t ach an L- shaped oi l gauge di r ect l y t o t he dr ai n hol e; s l udge wi l l

accumul at e i n t he bend and event ual l y c l og t he l evel .l I nst ead, at t ach t he oi l gauge t o a dr ai n pi pe i nser t ed i n t he dr ai n

hol e. Thi s way, any sl udge can be f l ushed out .2. Per manent l y mar k t he new oi l gauge wi t h t he same l evel as t he ol d gauge.

oi l hol e

oi l gauge

dr ai n

hole

i mpr oved oi l gauge

bl i nd val ve ( dr ai n hol e) and cl eani ng hol e

shor t pi pe ( l ong enough t o r each dr ai nage cont ai ner )

ni ppl e

ol d oi l gaug

e

T

446




(check one)

X


Date: Revision Date

Theme: I s t he hydr aul i c uni t wor k i ng nor mal l y? ( par t 2)

I f machi ne cycl es r emai n sl ow at l ow t emper at ur es even af t er c l eani ng out t he hydr aul i c uni t as descr i bed i n Par t 1, you need t o move t o t he next l evel of count er measur es. But her e ar e some quest i ons t o ask bef or e you do:

1. What t ype of hydr aul i c par t s ar e used i n t he uni t ?

2. Does t he uni t conf or m t o t he hydr aul i c r out i ng di agr am? ( Check pi pe di amet er s, f or exampl e. )

Ol der f l ow cont r ol val ves ( 20- 50 l / mi n. or l ess) ar e t ypi cal l y not equi pped wi t h t emper at ur e compensat or s. As a r esul t , changes i n hydr aul i c f l ui d v i scosi t y due t o t emper at ur e f l uct uat i ons may cause f l ui di t y t o var y by 10 t o 20 per cent .

I n envi r onment s wher e such cycl e t i me f l uct uat i ons pose a pr obl em, t r y i nst al l i ng a f l ow cont r ol l er equi pped wi t h a t emper at ur e compensat or mechani sm.

447




(check one)

X


Date: Revision Date

Theme: An Exampl e of Rest or at i on

An Exampl e of Rest or at i onCycl e di agr am

Pr obl em Tr eat ment

The mi cr oadj ust ment of t he val ve t hat adj ust s t he f i ni sh f eed speed di dn’ t wor k.

The l oadi ng speed was sl ow and t he nongr i ndi ng per i ods wer e t oo l ong.

The cam pl at e had devel oped r i dges, and t he val ve coul d not adj ust t he f l ow cor r ect l y. We r epl aced t he cam pl at e.Ther e was debr i s

adher i ng t o t he t i p of t he speed cont r ol val ve.

We t ook t he val ve apar t and cl eaned i t .

448

Basic Information Lesson - Sample 1•This example of an information lesson makes extensive use of simple graphics to explain which things contaminate hydraulic fluid. Graphics often clarify concepts and make them easier to remember. The lesson would be delivered orally, with this sheet serving as a visual aid. Afterwards, this sheet will be made available for reference. The information will eventually be incorporated in the standard procedures.

Wat er

Ai rHeat Di r t & Gr i me

I ce f or mat i onVi br at i on

Rubbed- of f par t i c l es

Oi l oxi des Pai nt Seal i ng t apeNew l ubr i cant suppl y schedul e

Rust

Cont ami nat i on of Hydr aul i c Fl ui d

Machi ne i n oper at i on ( wi t h cut t i ng debr i s, sand, et c. )

449

Basic Information Lesson - Sample 2• This is a continuation of the one-point lesson on hydraulic contaminati

on shown on the prior page.

Hydr aul i c Devi ce and Cont ami nat i on

Exampl e Sect i on

Speci f i ed cl ear ance r ange ( mi cr ons)

Poppet val ve 13 　 40

Vane pump( vane si des)

5 　 13

Val ve( spool & sl eeve)

1 　 23

Gear box( gear wheel & si de pl at e)

0. 5 　 5

Because t he hydr aul i c devi ce has such nar r ow i nt er nal c l ear ance spaces, i t cannot t ol er at e much cont ami nat i on and st i l l oper at e ef f i c i ent l y.

Cont ami nat i on i s t he No. 1 enemy of hydr aul i c equi pment .

lAr e any unnecessar y hol es bei ng l ef t i n t he equi pment ?lI s dr ai n pi pe pr oper l y i nser t ed i nt o t ank?lI s l i d on oi l suppl y hol e f ast ened secur el y?

Car r y out i mpr ovement measur es at al l l ocat i ons wher e cont ami nant s may ent er t he equi pment .

450

One-Point Lesson

Theme: How t o adj ust ai r pr essur e on t he Fycon Fi ni sh Appl i cat or

l I f t he pr ocess i s i n cont r ol , t he needl e wi l l be poi nt i ng i nsi de t he GREEN pai nt ed sect i on of t he pr essur e gauge.

l I f t he pr ocess i s out of cont r ol , t he needl e wi l l be poi nt i ng i nsi de t he RED pai nt ed sect i on of t he pr essur e gauge.

l I f t he pr ocess i s out of cont r ol ( oper at i ng i n t he RED ar ea of t he gauge) , adj ust t he r egul at or unt i l t he needl e r et ur ns t o t he GREEN pai nt ed sect i on of t he gauge.

det ai l of pr essur e gauge on r egul at or

451

Grease Fittings

1. Gr ease f i t t i ng shoul d al ways be si l ver ; Never pai nt over one!

2. Do not st r i ke f i t t i ng wi t h anyt hi ng.3. I f t he f i t t i ng has dent s or wi l l not accept

gr ease, r epl ace i t !

452

One Point Lesson: Red Tagging

• Any time you find an unneeded item, Red Tag It!

uFi r st , wr i t e a Red Tag and at t ach i t , f ol l owi ng t he di spl ayed st eps.uThen, br i ng t he i t em t o t he Red Tag Hol di ng Ar ea.

1. Wr i t e your name

2. Recor d t he dat e

3. Recor d l ocat i on of f ound i t em

4. Recor d r eason f or t aggi ng

5. Make suggest i on f or r esol ut i on

Name: Tom F. Date: 8/21/99

Item: Electric Drill

Location of Item: Door Assembly Area Floor

Reason for Red Tagging: Broken handle

Suggested Disposition: Discard, not fixable

453




(check one)

X

Written by: Reference # Location:

Date: Revision Date

Theme: The Two- Bi n Syst em f or I nst ant Mai nt enance Par t s

Use a cont ai ner di vi ded i nt o t wo bi ns; st ar t wi t h bot h s i des f ul l .

Put a kanban ( or der car d) i n each si de.

Sl i de t he l i d t o cover s i de B.

Post t he kanban f r om si de A and begi n usi ng par t s.

The kanban wi l l pr ocur e mor e par t s f or s i de A.

When t he par t s on si de A ar e used up, s l i de t he l i d and begi n usi ng si de B par t s.

Post t he kanban f or s i de B.

When t he or der ed par t s ar r i ve, put t hem i n s i de A

Cont i nue t o r epeat st eps and

Par t # 20-08010018- 0

Name: Gui de pi n

Or der quant i t y : 50 uni t s

454




(check one)

X

Theme: Hydr aul i c Power Uni t I nspect i on

Pur pose of I nspect i onThe hydr aul i c power uni t pr ovi des power t o t he ent i r e hydr aul i c syst em. Even i f you use t he r i ght amount of oi l , l ocal oi l shor t ages, c l ogged f i l t er s, or ot her causes may r esul t i n cavi t at i on. *Thi s can cause pr obl ems ( noi se, cor r osi on, pr essur e f l uct uat i ons, or v i br at i on) i n hydr aul i c devi ces t hr oughout t he syst em, so dai l y checks ar e essent i al .What t o Check and HowDai l y checks can be per f or med dur i ng oper at i on and consi st of l ooki ng f or abnor mal i t i es usi ng t emper at ur e and ot her gauges, as wel l as t he human senses of s i ght , hear i ng and t ouch.

1. Check Oi l Vol umeWhen t he oi l dr ops bel ow t he l ower i ndi cat or l i ne of t he oi l vol ume gauge, t he suct i on f i l t er pul l s i n ai r and ai r ent er s t he r et ur n t ube. Add oi l when t hi s occur s.2. Check Suct i on Fi l t erA cl ogged suct i on f i l t er causes ai r t o ent er t he syst em. Remove t he f i l t er t o check. I f cont ami nat i on i s l i ght , wash wi t h det er gent oi l and r epl ace t he f i l t er . Repl ace t he f i l t er i f cont ami nat i on i s heavy. Consi der us i ng a bar r i er t o keep cont ami nant s away f r om t he oi l i nt ake.

Bad Exampl epr essure gauge

oi l r et ur n

mot orpump

oi l l evel gauge

suct i on f i l t er

455

Written by: Reference #

Location:

Date: Revision Date

3. Check Suct i on Joi nt s, Gasket s, and Pi pesTi ght en any l oose j oi nt s. Repl ace any det er i or at ed gasket s. Check f or hai r l i ne cr acks i n pi pes and r epai r or r epl ace i f any ar e f ound.

* When a l ocal dr op i n oi l pr essur e occur s, di ssol ved ai r escapes i n t he f or m of bubbl es. When r api d pr essur e i s t hen appl i ed, t he ai r has no t i me t o r edi ssol ve and t he ai r becomes super compr essed and causes noi se as i t st r i kes a sur f ace. Thi s i s cal l ed cavi t at i on.

bar r i ercont ami nant s

oi l r et ur n mot or

pump

pr essure gauge

Good Exampl e

autonomous maintenance

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