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Tpm.training

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Jishu Hozen – autonomous Maintenance

Purpose :

1. Training of operators to be proficient in equipment2. Protecting ones own equipment

Members:1. Operators2. Line leaders3. supervisors

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JISHU HOZEN

““Jishu Hozen” is the activities which Jishu Hozen” is the activities which each operator performs -daily inspection ,each operator performs -daily inspection ,lubrication, parts replacement, repair, lubrication, parts replacement, repair, trouble-shooting, accuracy checks andtrouble-shooting, accuracy checks andso forth on his own equipment, aiming atso forth on his own equipment, aiming atachieving the goal of keeping “one’s own achieving the goal of keeping “one’s own equipment in good condition by one self equipment in good condition by one self ””

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Jishu Hozen – 7 Steps

1. Initial Clean up

2. Counter Measures

3. Tentative standards

4. General Inspection

5. Autonomous Inspection

6. standardisation

7. Autonomous Management

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Jishu - HozenSteps for developing

1. Initial Cleaning(inspection)

• All- around clean-up of dust and dirt on equipment.

• Oiling and re-tightening of bolts and nuts

• Finding and restoration of “Fuguai” (abnormalities)

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So Cleaning is…ESSENTIALPurpose of cleaning

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DIS COVER ---- DISCOVER-

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WHAT TO CHECK ?• Loose bolts & nuts.• Loose wires.• Missing parts.• Rusted parts.• Broken parts.• Cracked parts.• Air leaks• Oil leaks• Coolant leaks.• Dirt, dust and cobwebs.• Oil on the floor.• Scrap around the machine.• Burr and swarf around the machine.• Abnormal heat.• Abnormal sound.• Abnormal vibration.

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Step 1: Initial Clean up

a. Formation of JH circlesb. division of machine pars to operatorsc. Training on abnormality identificationd. Preparation of red & white tags

a. White tags – for abnormality that can be corrected by unskilled personb. Red tags – for abnormality that can be corrected by skilled person

e. Keeping cleaning tools readyf. fixing time for JH Activityg. Cleaning all parts of the machine – even opening of parts are necessaryh. Inspection of parts during cleaning activityi. Identification and tagging of abnormality and recordingj. Identify difficult to access areas around the machine-In-Accessible(IA)k. Identify the SOC – source of contamination after cleaningl. Record in the matrix – red & white tags,IA,SOC

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Baniyan waste

To clean small burr & coolant

Nylon brush


Tools used for cleaning

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Wire brush


Spanners

To tighten loose bolts & nuts


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Showel

To clean big burr & swarf

Screw drivers

To tighten loose screws


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Allen Keys

To remove screws


Allen Keys

To remove hard/ solidified burr & dust

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Step 1: Initial Clean upa. Formation of JH circlesb. division of machine pars to operators

Machine no:

Circle No:

Circle Leader:

Circle Members:1234

Machine Parts: Responsibility:123456

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Step 1: Initial Clean up• Record in the matrix – red & white tags,IA,SOC

Tag MatrixMachine No:Circle No:

Slno M/c Parts dust Leak Loose Missing vibration noise Broken Wornout nonStd others total

123456789

101112131415

P = Tags put R= Tags RemovedPR

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Step 1: Initial Clean up• Record in the matrix – red & white tags,IA,SOC

Source of Contaminantion

slno contaminant source Why Why why Why countermeasure1234567

InAccessible / difficult to Clean,Lubricate,Inspect,Re-tighten - CLIR

slno Area CLIR Why Why why Why countermeasure1234567

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Step 1: Initial Clean up

Countermeasure Plan for Red/ white/ IA/ SOC

slno abnormality Tgt Dt Resp12345678

Action Plan

0

5

10

15

20

25No of tags

Failure Setup Yield Defect Motion

Tags linked to losses

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2. Countermeasures for sources of problems and difficult places

• Eliminate causes for dirt and dust.

• Improve places which are difficult to clean, lubricate, and re-tightening of bolts and nuts.

• Reduce time for clean-up and oiling.

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Step 2: Countermeasures for SOC/IA/others

a. Taking actions on all abnormalitiesb. eliminating difficult to access areasc. Eliminating SOC d. Machine ‘ CLEAN Without Cleaning’ statuse. Various kaizens implementedf. Machine ready for tentative standard preparationg. Step2 audit passed

Tags Put Vs Removed - cumulative for HSL9

0

50

100

150

200

250

Aug-04 Sep-04 Oct-04 Nov-04 Dec-04 Jan-05

No of tags

Tags put Tags removed

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Before After

JH 2nd step

Easy to clean / Hard to access area

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Before After

JH 2nd StepEasy to lubricate

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Before After

JH 2nd step

Easy to inspect and adjust

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3. Establishing Tentative Standards for “Jishu-Hozen”

• Make temporary procedures or manual of Autonomous Maintenance for cleanup, lubrication, re-tightening, checkups.

• (Specify the time allocation for various maintenance daily or regularly held.)

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Step 3: Preparation of Tentative standards

a. Making a list of Cleaning, Lubrication,Inspection & Re-tigthening pointsb. arriving at method and frequency of CLIRc. dividing the CLIR into mahine zonesd. Preparation of standards chart with visual aidse. Education of operators on standardsf. Practising the standards for minimum 1 monthg. Update new check pointsh. Have step 3 audit Passes

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Jishu Hozen – 7 StepsStep 3: Preparation of Tentative standards

JH Tentative Checksheets

MONTH : M/ C NO :

SL NO

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

RUNNINGSTOPPED1 CLEANING RUNNING STOPPED

1.1Clean front side of machine ü Dy 60 Oper

1.2 Clean burrs in bedü

Wk 300 Oper

1.5.Clean coolant tank ü

Dy 60 oper

2 INSPECTION2.1 Hyd.oil level (should be in green band) ü Dy 10 Oper Top up oil

2.3 Lub.oil level ü Dy 10 Oper Top up oil

Lub oil pressure(Within green band ) ü Dy 10 Oper Inform

supervisor2.4 Hyd.system pressure (green band) ü Dy 10 Oper

Inform supervisor

2.6 Abnormal noise ,heat in hydraulic motors ü Daily 30 Oper Inform

supervisor2.6 Abnormal noise ,heat in coolant motors ü Daily 30 Oper Inform

supervisor2.6 Abnormal noise ,heat in lub motors ü Daily 30 Oper Inform

supervisorCheck lub oil pressure(within green band) ü Daily 10 Oper Inform

supervisor2.1 Cutting oil level (should be in green band) ü Daily 10 Oper Inform

supervisor

RESP

ACTION IF ABNORMA

L

M/ C STATUS

DATEACTIVITY HOW

FREQ

TIM

E (S

EC)

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4. Overall Inspection

• Training in check-up skills through checkup manuals.

• Find and restore slight defects through general inspection.

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Jishu Hozen – 7 StepsStep 4: Preparation of General Inspection

Bolts & Nuts Pneumatics Hydraulics Electrical Drives Fits/tolerances Safety Process

condition

2

TopicsSl

No. Emp. No. Name M/c No

11

3

4

5

6

7

8

9

10

JH Step 4 Training

1

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5. Autonomous Inspection

• Formulation and implementation of clean-up and oiling lubricate criteria and autonomous inspection check sheet which can be performed efficiently and positively.

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6. Standardization• Standardize various types of field management items. Establish the system to thoroughly maintain and control them.– Establish logistics standard– Standardization of data records– Standardization of die, tool and

jig management– Process quality assurance

standard, etc.

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7. Autonomous Management

• Continue to develop corporate policy and commitment target and conduct “Kaizen” activities regularly, and record the data analyzed through MTBF to improve the equipment.

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TPM Vs initiatives at Wada

sixsigmacomm.eff

scrap redn d/t redn

Meas.Print

cust.Compl.

Vendor Dev. RTY ImpCOQ HMP GMP Tool.Imp M/c Imp

Spares.Mgmt Projects

1 KK

2 JH

3 QM

4 PM

5 Otpm

6 E&T

7 SHE

8 Ifc

9 Ttpm

TPMDouble E initiatives Quality Initiatives Projects

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Documents

jh 2nd stepeasy

matrix red

initial clean

initial clean

6 abnormal

white tags

green band

machine pars