(Step 0-3)
1
AUTONOMOUS MAINTENANCE Kinerja
FI Standard
Forced Deterioration
PM
2
AUTONOMOUS MAINTENANCE Kinerja
FI Standard
Forced Deterioration
PM
2
J ISHU HOZEN HOZEN PENGERTIAN Peme meliha lihara raa an ma mandiri ndiri ada dala lah h ke kegia giata tan n dima dimana na s et et ia iap k ar ar ya yaw an an m el el ak ak sa san ak ak an an t ug ug as as -t -t ug ug as as h ar i an p ad a p er al at an n y a s en d i r i y an g m el el ip ip ut ut i i ns ns p ek ek s i, i, p el um um as as an , p en en g ga gan t i an an kompon kom pone en, re repa para rasi, si, me menga ngata tasi si ga gangg nggua uan, n, uji ak u r as i , d l l d en g an t u j u an ag ar k o n d i s i pera pe rala lata tan n da dapa patt dij dija aga se sendi ndiri ri kon kondis disiny inya a ole oleh h si pe pengg ngguna una..
Saya menjalankan, Anda membenarkan
Saya menjalankan, Saya membenarkan 3
Tujuan Program AM
Tujuan program AM adalah: benar dan pengecekan harian membawa peralatan kepada kondisi idealnya melalui
restoration (pengembalian ke keadaan semula) dan proper management (manajemen yg sesuai) peralatan terpelihara dengan baik Tujuan penting lainnya adalah untuk Perubahan Cara Kerja
4
Step (Tahapan) AM
STEP. 7 STEP. 6 STEP. 5 STEP. 4
All Out Autonomous Management
Standardization (Buat standard yg Baku)
Autonomous Inspection (Lakukan Inspeks i l angkah S1-4 lagi)
General Inspection (Standarisasi alat, Ling kung an kerja & proses kerja)
STEP . 3 Tentative Stand ard (Buatkan Standard s ementara) STEP. 2
Counter measures for causes of deterioration & hard to access area (Mencarari sumb er masalah, Hilangk an sumber & b uat pembersih an mudah)
. STEP. 0 Preparation (Persiapan)
5
Pengertian AM AM : Cara lain melihatnya…. melihatnya…. Step 7 Mempersiapkan bayi untuk tantangan Step 6
Baby log book
Kunjungan rutin
Step 5 Berbagi tanggung jawab!
s e n i c c a v
Step 0 Persiapan untuk sang bayi
Step 1 Pembersihan awal Step 2 Mencari sumber masalah/ area yang sulit di akses
Step 4 Meningkatkan pengetahuan!
Step 3 harus dilakukan/diinpeksi 6
Pengertian AM: AM: Cara lain melihatnya…. melihatnya…. Bay
Orang tua
Do ter
Mesin
Operator
Teknisi
7
The Three Crown Jewels of
8
Tiga Mahkota AM AM
3 Mahkota AM: • Activity Boards (Papan Circle) • Team Meetings (Circle Meeting)
9
Story Board Autonomous Maintenance ep Nama Tim & Anggota
Master Plan Pabrik
Daftar Tag
Defect
No. of OPL
Peta/Gambar Section Policy 1. ---------------2. ---------------3. -----------------------------------
Team Policy
Issues: -----------------Policy: Target
Jadwal aktivitas AM
CLI Time act vs Std
Defect Graph
Master Plan Tim Tanggung Jawab Area/Mesin
OPL
Safety
Safety
Sumber pengotor
Sumber pengotor
y u diakses
y u diakses
Defect kritis
Defect kritis
Standar Antara
Graph
No. of Tag
Daftar
CLI std, procedure
Graph KAIZEN
10
Story Board – Factory Master Plan
AM Step 01 02 -2 -3 -4 -5 -6 -7
2001 ---- Month ---
12
01
2002 02 ----------
11
Story Board - Team Master Plan
Line A Step-1 Step-3 --------------------------------B Step-1 Step-2 Step-3 ---------------------------------
2001 01 02 03 04 05 06 07
----- Month -----
12
Story Board - AM AM Activity Time
Waktu 120
menurun dan rasio waktu improvement harus meningkat
100
dengan aktivitas AM.
80 Meeting Cleaning 40 20 0 an
Feb
Mar
A r
Ma
Tar et
13
Story Board - No. of Tag
No. of Tag 400
Kemam uan O erator: Mampu menemukan defect
350
No. of Tag on
300 250 200
. Tag off
150 100
Kemampuan Operator:
0 Jan
Feb
Mar
Apr
May
Target
14
Story Board - Cleaning Time Increasing
AM Activity Time 100 90
Meeting
80 70 60
Improvement
50 40 30
Cleaning
20 10
No. of Tag on: Meningkat
0 Jan
Mar
No. of Tag 120
Ketersediaan operator mene-
100 80 60
Tag on
40 20 0 Jan
Mar
15
Story Board - List of Tag: Safety
Daftar Bahaya
Line Name:
Team Name:
Equipment: No.
Location
Description
Date
Countermeasure
Request to
Name
Deadline
Completed
16
Story Board - List of Tag: Source of Dirt
Line Name:
Team Name:
Equipment: No.
Location
Description
Date
Countermeasure
Request to
Name
Deadline
Completed
17
Story Board - List of Tag: Hard to Access a tar area yang su t Line Name:
ang au Team Name:
Equipment: No.
Location
Description
Date
Countermeasure
Request to
Name
Deadline
Completed
18
Story Board - List of Tag: Critical Defect
Line Name:
Team Name:
Equipment: No.
Location
Description
Date
Countermeasure
Request to
Name
Deadline
Completed
19
Story Board - No. of One Point Lesson
No. of OPL 160 140 mprovemen
120
Safety Defect
100
60 40 20 0 an
Feb
Mar
A r
Ma
Tar et
20
Story Board - Imprevement Sheet Lembar Improvement Line Name:
Date:
Equipment:
Team Name:
Before
Comment:
After
Comment:
Benefit:
21
Story Board - Cleaning/Inspection/Lublication Time v as yang
a u an un u men apa an
re- en a ve
an ar
.
Time
140
Bagaimana menurunkan waktu
Lublication
1. Eliminasi sumber pengotor
Inspection
120
Cleaning
.
100
m nas area yg su
a ses
3. Manajemen visual
80
. 40
5. Standardisasi
20
6. Automatisasi
0
n a J
b e F
r r a p A M
y a M
3 p e t S
8 am/hari/shift x 60 mnt = 480 mnt/hari/shift Target: 10 menit
480 mnt x 2% = 9.6 mnt 22
Story Board - Tentative Standard
Pre-Tentative Standard” digunakan dari step ½ dan dimodifikasi selama step ½. Kemudian “Tentative Standard” (standar antara) arus uat pa a step . Bagaimana
Selama o erasi/tidak
Berapa lama
Kondisi yg benar C le a n i n g
D r a w in g
L u b r i c a t io n
Inspection
Gambar tangan, 3D, detail
L o c a tio n - - - - - - - - -- ----------------------------------------------------------------------------------
S ta n d a rd - - - - - - - -- - -
W hen
H ow
M eth o d
T im e
P e r io d
Prosedur, apabila kondisi tdk benar
operas s
, am a
an o om s
23
One Point Lesson
1. Basic knowledge 2. Troubleshooting 3. Improvement
24
Contoh One Point Lesson
25
Contoh One Point Lesson
Visual Control Valve Hopper bisa dilihat jelas, bila valve membuka maka alatnya bergerak seolah memompa liquid dari Buffer & bila liquid mencapai maximum, valve menutup maka alatnya Tanggal Pelaksanaan
Tanda Tangan Nama
26
Meetings
27
AUTONOMOUS MAINTENANCE
28
JISHU HOZEN
Di step 1 diterapkan motto “ Pembersihan adalah inspeksi” dalam prakteknya.
29
JISHU HOZEN - Step 1 TUJUAN
- Mencegah kerusakan yang disebabkan debu dan kerak -
Personil - Menyentuh peralatan mengembangkan rasa memiliki terhadap peralatan - Melatih mata untuk mendeteksi fuguai dari peralatan - Mempelajari fungsi dan struktur dari peralatan - Mengetahui titi k lemah dari peralatan
30
JISHU HOZEN - Step 1
•
Pembersihan adalah inspeksi Hal-hal yg penting untuk diperhatikan:
-
Nomer satu pengamanan
-
Operator melakukan sendiri pembersihan sebagai pekerjaan normal
-
Bersihkan semua kotoran yg telah menumpuk bertahun-tahun
-
Buka tutup-tutup yg belum pernah dibuka dan bersihkan o oran- o oran yg menempe
-
Bersihkan ko toran tdk hanya dari peralatan itu sendir i, tetapi juga dari peralatan transfer, kotak-kotak/panel-panel listrik, tanki-tanki fluida yg ada di dalam dan peralatan bantu lainnya
-
Jangan putus asa jika peralatan cepat koto r kembali setelah dibersihkan. Perhatikan sebera a ce at kotorn a kembali dari mana dan bagaimana terjadiny a. 31
JISHU HOZEN - Step1
Pembesihan
Pengecekan
Menemukan abnormality
Efek Positive Kebanggaan
Rasa memiliki
Disiplin
Tanggung Jawab
Kebiasaan
Perilaku
Budaya
32
PEMBERSIHAN ADALAH INSPEKSI Membersihkan alat secara menyeluruh
bagian dari peralatan
Mendeteksi bagian yang rusak dari peralatan
Daftar area yg defektif
Identifikasi area yg sulit dibersihkan
a ar area yg su
Sumber kontaminasi Yg terlihat
Daftar sumber kontaminasi
Normal? atau Abnormal?
a ar per anyaan
Cacat yg tersembunyi menjadi nampak 33
REDUCE CLEANING TIME ELIMINATE
NO
ATTACKING DIRT
YES
REDUCE
NO
COUNTER MEASURES FOR HTC
YES
CONTAIN
NO
GUARDS
YES
SCREEN
YES
PAN/TRAY
FAN/CHIMNEY
NO
DIRECT 34
TPM
TPM
Step No: 1 2 3 4 5 6 7
Step No: 1 2 3 4 5 6 7
ABNORMALITY
ABNORMALITY
Control No: Date Found: Found by: Description of Abnormality:
Equipment: Control/PK No: Date Found:
Description of Abnormality:
35
JISHU HOZEN - TAG COUNT TYPES OF FUGUAIS
TYPE
TYPE
TYPE
TYPE
TYPE
TYPE
TYPE
1
2
3
4
5
6
7
TAGS
DUST
LOOSE
MISSING
HOLES
EXCESS NOISE
HARD TO PERFORM
OTHERS
ATTA CHED
DIRT
CHATTERING
WEAR
EXCESS HEAT
JH ACTIVITY
SPILLAGE
ECCENTRIC
CHIPPED
ODOUR DISCOLOURATION
LEAKAGE
INCLINED
BENT
SCRATCH
VIBRATING
BROKEN
RUST
EXCESS MOMENT
DENTED
TOTAL
SPLASH
LOCATI ON OF FUGUAI , OF EQUIPMENT
,
WIRINGS,VALVES,3-POINT SET,ETC
DOORS/INSIDE OF
SAFETY COVER,OPERATION/
COVERS
CONTROL PANEL,INSPECTION HOLE,ETC WORING OIL,LUBRICATION
ASSOCIATED EQUIPMENTS
TANK,HYDRAULIC UNIT
PERIPHERAL
MEASURING INSTRUMENT,JIGS
EQUIPMENTS
WORKING TABLES, TOOLS,
ETC
ETC
TRANSPORTATION
CHUTE,CONVEYORS, ,
AROUND EQUIPMENT
FLOOR.PIT, WALL, CEILINGS ETC
INSIDE MACHINE AND GEARS,CAMS,CHAINS,SHAFT MACHINE PARTS
PULLEYS,SPROKETS,ETC
TOTAL T AGS ATTACHED TOTAL TAGS DETACHED
36
Step 1 - Master Plan
Activi ty
Mon th 1
n a sa on o s ep 2
Mon th 2
Mon th 3
Month 4 Mon th 5
n a c ean ng
Tagging on machine(With the knowledge of different categories.viz. Safety,Minor defect etc. .
4
Resolution of Tags attached.
5
Meeting of circle
6
Identifying the Hard to access/clean& lubricate area. Also difficult to inspect area.
7
Preparation of OPL
8 Audi ts fo r co mpl etion of step no .1 Start of activity
Finish of activity
Sustain activity
Activi ty inp ro ce ss
37 HLL - Silvassa Beverages
Step 1: Initial Cleaning Activities e ore
Cleaning focused at eliminating Long Deposited Contaminations Com lete Partici ation from Circle Teams and Line Management Basic awareness provided to the Objectives 38
Step 1: Daftar Fuguai Diskusi Tag
Identifikasi Fuguai
Pembuatan ag
Diskusi dengan tim engineering
Pembuatan a zen
Eliminasi ugua
Update progr es ke tim circle
Logging of Result; Know-Why OPL; s an ar
Tag dikon versi menjadi kaizen
39
Apa itu " Fuguai Fuguai"? "?
Fuguai = deviasi (penyimpangan)
- Kegagalan fungsi - Sulit untuk diakses / observasi - Susah diperiksa a aman
40 In Associ ation with
Pembersihan adalah inspeksi yang terbaik! terbaik !
41 In Associ ation with
Bagaimana mengenali " Fuguai Fuguai"? "?
Meggunakan 5 indra:
Lihat Dengar
--> menggunakan mata untuk mengobservasi --> mendengarkan dan mencoba meng-
Cium Sentuh Rasa
--> mencoba mengenali bau yang aneh --> mencoba merasakan panas, vibrasi --> secara normal tdk direkomendasikan, tapi kadang2 dapat dilakukan dgn hati2
Menggunakan otak: Berpikir sebelum membuat keputusan!
42 In Associ ation with
5 INDRA
43 In Associ ation with
Bagaimana menemukan " Fuguai Fuguai"? "?
Tahap 1 - Observasi Sebelum melakukan apapun, pertama kali observasi mesin secara keseluruhan untuk menemukan semua defect/cacat an terlihat
Tahap 2 - Pembersihan (fase pertama) Membersihkan mesin secara keseluruhan a ar semua defect an tersembun i dapat ditemukan (tidak tertutupi)
– Pembongkaran bagian utama dari mesin, dan jika mungkin, temukan defect yang terlihat seperti yang telah dilakukan pada tahap 1
Tahap 4 - Pembersihan (fase kedua) Membersihkan bagian2 dan komponen2 yang dapat diakses setelah
Tahap 5 - Perakitan
44 In Associ ation with
Membersihkan dengan berpikir berpikir adalah menemukan “ fuguai” fuguai”
45 In Associ ation with
Step 1: List of HTA & SOC Daftar Hard to Access Areas area sulit di an kau dan Source of Contaminations (sumber kontaminasi) yang disiapkan oleh tim selama step 1 sebagai persiapan untuk step 2.
r i e b s m n u i S m a r t a n t f o a D
g u y a a k g e r n a A j r i a d t i f t l D S 46
Contoh pembersihan awal & setelah menghilangkan abnormality
DG Area
Compressor Ar ea
47
Standar Antara AUTONOMOUS MAINTENA NCE STA NDAR D (Clean ing , Chec ki ng , and Lubricating) Equipment :
Group :
Panther
Pr epared :
Leader :
Mr.Fulan bi n Ful an
16.11.2000
Revised :
Flex Tag No :
L oca ti on :
Pa cki ng Ha ll an ar
T P M
HORIZONTAL SEALER
FILLING NOZZLES
No lamination,No shampoo
Batch cutter blade
No Lamination,no shampoo,
Sealing jaws
Flexible Hose
Motor
MAIN DRIVE
o
Sealing Surface
ll .
VERTICAL SEA LER
e
,
Acti on if Required
oo
Clean
Time (Min)
Interval espons Shift
Daily
Week ly
Monthly
y
Quar ter ly
2 minutes D254,D246,D122
i .
Clean
l
2 minutes
D69,D110,D304
i
1 minutes
,
,
No laminate,No smampoo,
No shampoo
Clean
2 minutes
D86,D302,D417
Clean
2 minutes
D69,D110,D306
Clean
2 minutes
D86,D302,D417
Clean
3 Minutes
2 Minutes
No dust,
Clutch break assembly
No dust,
Colleting drive
No shampoo,
Clean
D254,D246,D122
D254,D246,D122 Dancing roller
No Dust
Clean
Ins ide area
No Dus t
Clean
D86,D302,D417
48
Ste 02 Eliminasi area yg sulit dijangkau sumber kontaminasi 49
u uan dan pengkerakan serta berusaha memperbaiki bagian-bagian yg sukar dibersihkan atau dilumasi sehingga pelaksanaan pe er aan-pe er aan tu e mu a an cepat.
50
Step 2: Tindakan terhadap HTA
BEFORE
Covers on the rare side of Plodder made transparent for Ease in Inspection
AFTER
BEFORE
Covers on the sid e of Plodder Made Transparent for Ease in Inspectio n
AFTER
51
Step 2: Tindakan terhadap HTA
BEFORE
BEFORE
Covers on t he sides of Roll Mill made transparent for ease in i nspection Roll Mill Motor relocated to the top t o elimin ate Hard to Acc ess Area
AFTER
AFTER
52
Step 2: Tindakan terhadap HTA
BEFORE
The cover on the Gearbox made transparent for im mediate inspection during running of machine.
AFTER
BEFORE
Hard to Access Area removed fo r adjust ment on ACMA
AFTER
53
Step 2: Tindakan terhadap SOC
BEFORE
Faulty Lip s eals were a major sour ce of cont amination in the Sachet Filling Assembly
BEFORE
Covers installed to guard against dust.
AFTER
A
54
Step 2: Tindakan terhadap SOC
BEFORE
BEFORE
Contamination of electri cal septical due to improper posi tion of ho pper drain line.
AFTER
Chute installed to revent em t cartons from fallin down
55
Contoh -AM Step 2-
Tindakan terhadap sumber pengotoran
56
Contoh -AM Step 2-
Tindakan terhadap sumber pengotoran Before
After
57
Contoh -AM Step 2-
Tindakan terhadap sumber pengotoran
Before
After
58
Contoh -AM Step 2-
Tindakan terhadap sumber pengotoran Modifikasi eralatan untuk mem ermudah pembersihan dan pelumasan Before
After
59
Contoh -AM Step 2-
Tindakan terhadap area yg sulit dijangkau Modifikasi peralatan untuk mempermudah pembersihan dan pelumasan Before
After
60
Contoh -AM Step 2-
Tindakan terhadap area yg sulit dijangkau Install cover dan jendela transparan untuk membuat pengecekan lebih mudah After
61
CLI Standards
62
JISHU HOZEN - StepStep -3 tep : em uatan tan ar ntara
u uan: . Selain itu juga meningkatkan keandalan peralatan dengan membuat serta melaksanakan standard sementara yg dapat
Standard meliputi Pembersihan (Cleaning), Pelumasan (Lubricatin ), dan Pen encan an Baut-baut (Ti htenin )
63
CLIT* tidak dilakukan
70%
*
=
Kerusakan yg tdk dipantau
yg uru
30%
Tidak mengikuti prosedur operasi SOP
Masalah yang hanya engineering (produksi dan maintenance)
Masalah yang dapat cega engan
, Tightening (Pengencangan)
,
,
64 In Associ ation with
65
Area:
H&B:
TSO:
Line #
5
Machine
Filler /Capper
Bejo st
Line Leader
1 Draft
Location
M/C Status
Inspection
Action Method
C L E A N I N G
P. Schier
15/12/97
M. Bite
19/01/00
nd
Revision 2:
Standard
Date:
2 Draft
Ref Drawing:
No
Compiled By:
1.
Filler vacuum pot.
Cleaned free of liquid
Stopped
Visual
2.
Capper vacuum pot
Cleaned free of plastic debris .
Stopped
Visual
3.
Filler bed
Cleaned free from liquid or spills
Stopped
Visual / touch
4.
Filler doors
Cleaned free from liquid and dust
Stopped
Visual
5.
Keystation
Clean free of product
Running
Visual /touch
6.
Plate & plate covers
Cleaned free of product
Stopped
Visual /touch
7.
Cap Plate
Clean free of liquid
Stopped
Visual
Remove pot & rinse with hot water Remove pot & rinse with hot water Wipe clean with alcohol and paper towel Wipe down with Jif glass and paper towel Wipe down with alcohol and paper towel Wipe down with alcohol and paper towel Wipe down with alcohol and paper towel
Time Mins Tool(s) Hot water
Intervals D
2min
W
F
Person in Charge M Operator
Hot water
2min
Operator
Alcohol and paper towel
5min
Operator
Jif glass and paper towel
5min
Operator
Alcohol and paper towel
2min
Operator
Alcohol and paper towel
5min
Operator
Alcohol and paper towel
1min
Operator
66
Area:
H&B:
L in e #
TSO:
5
M ach in e
Pat C olem an st
L ine L ead er
1 D raft
Filler /C ap p er
2
R ef D raw ing:
No
nd
Standard
M/C Status
Inspection
Action Method
1. . N S P E C
3. 4. .
I O N
6.
Capping plate leads ompresse air valve Oil gauge vacuum pump Guarding bolt around filler a es p a e cover Gearbox oil gauge (rear of filler)
Check for damage ec
n green zone Check if in zone Check no screws or bolts missing ec or burrs,chips or plastic shavings Check oil level is between markings
Stopped
D ate:
P. S ch ier
15/12/97
M . B ite
19/01/00
Draft
R evision 2:
Location
C om piled B y:
Time Mins Tool(s)
Intervals D
W
F
Person in Charge M
Visual / touch sua
None
1min
Operator
one
mn
pera or
Running
Visual
None
1min
Operator
Running
Visual
None
1min
Operator
oppe
sua touch
one
mn
pera or
Running
Visual
None
1min
Operator
unn ng
Try turning screws by hand
. air pot 8.
Capping head
9.
Capping plate
filled to marking and is not damaged Check the end of nozzle for burrs Check leads are not
10.
Filler guide rails
Check are not damaged
touch Stopped
leaking None
1min
Operator
Stopped
Visual / touch Visual /
None
1min
Operator
Stopped
Visual
None
2min
Operator
67
CLI records attached to equipment
68
Cleaning & Inspection Calendar
69
CLI standards and records at the line
Operator lub ricating machine
, 70
STEP 3 (TENTATIVE STANDARDS)
71
74
75
76
77
