5 Quality Maintenence

TPM Club India

Quality Maintenance Pillar

PILLAR Hinshitsu Hozen or Quality Maintenance Maintenance

1

TPM Club India


“Hinshitsu-Hozen” What is “Hinshitsu-Hozen? To maintain integrity of quality (state (st ate of 100% non-defectives) *

Condition setting : Set conditions for zero defects aimed at equipment and processes that do not produce quality defects.

*

Daily and periodical inspections : Inspect and measure conditions in time series.

*

Quality preventive maintenance : Prevent quality defects by maintaining measured values within the standard

*

Trend control and predictive maintenance : Predict possibilities of quality defects occurring occurr ing by observing trends of measured values.

*

Prior countermeasures: Take measures beforehand

© JIPM, 1994

2

TPM Club India


Hinshitsu – Hozen Concept Caused by raw material conditions Producing materials and energy not to generate defects

Quality Defect Factors Caused by equipment Caused by method precision conditions

Manufacturing equipment not to generate defect

Devising methods not to generate defects

Quality Assurance + Equipment and environment management

PM Analysis

Design check

Fostering operators proficient in equipment and job

Jishu-Hozen activities +

Material Management

Skill Education and Training

Pursue relationship between quality characteristics and material and energy condition / equipment precision / method conditions

Set conditions of generate defects

Caused by conditions of people involved

equipment

not

to

Maintenance and management ability training (Ability to find cause system troubles and to quickly and correctly take actions)

Management of conditions not to generate defects (Hinshitsu – Hozen)

Zero quality defects

© JIPM, 1987

3

TPM Club India


Relation among 5 Principles of TPM Development and Quality Maintenance Quality maintenance - Making of equipment which will not make poor quality products.

Individual Improvement

PM Analysis Basic Thinking of Improvement

Autonomous Maintenance

Restoration Pursuit of the optimal Condition Elimination of Minor Defects Adjustments Clarification of Skill 7 Steps of Autonomous Maintenance

Setting of Conditions (Technical Aspect) Decide properly

Condition Control (Control Aspect) Observe precisely

• Daily Inspection • Proper Operation

Preventive Maintenance MP Design

Application of Equipment Diagnosing Technology Feedback

Realization of

Education and Training

Zero-Defect

Fostering of personnel who thoroughly understand the equipment

4

TPM Club India


Concept of the Promotion of Quality Maintenance To promote quality maintenance, it is necessary to satisfy the following two precondition preconditions: s: • Forced machine deterioration has been thoroughly removed. • Natural deterioration removal under is progresses. • Managers and operators have become skillful with equipment, so that the functions and structure of equipment are well understood by them. • Have Sufficient inspection skill. • Training of staff who handle equipment on skill. • Jishu-Hozen, Kobetsu-Kaizen, PM analysis training, and skill education and training must be enforced 5

TPM Club India


Choosing time of quality maintenance. maintenance. • Total Jishu Hozen Implementation. • Workshop is free from fr om forced deterioration. •"when failures cannot be reduced, defects cannot be reduced.” • Losses such as Equipment failure, Minor Stoppages, Process failure are under control. c ontrol. •All relevant data on Quality defects is available. available.

6

TPM Club India


Implementation Procedure for Quality Maintenance •

Understanding quality defect phenomena.

•

Setting of standard values for inspection items and confirmation of results

•

Concentration

of

inspection

items

and

shortening of inspection time •

Drafting of QM (Quality Maintenance) matrix and reflection in standards

7

TPM Club India


Implementation Procedure for Quality Maintenance (contd…) •

Master plan for QM

•

3M Analysis

•

PM analysis for exposure and handling of malfunctions

•

Kaizens and Poka Yoke for eliminating defects

•

Maintaining Zero Defect

•

Process capability improvement plan 8

TPM Club India


Understanding quality defect phenomena

• Clarity on the definition of the defect • Frequency of occurrence and effect of defects

9

TPM Club India


Defects classification A - Type defect

B - Type defect

OK

OK

NOT OK

NOT OK

NOT OK

Action taken by operator

LSL

OK

C - Type defect

USL

• The output is (OK) initially • Becomes (NG) • Corrective action is taken by operator • Becomes (OK) • Uue Why – Why Analysis

No action by operator

LSL

OK

USL

• The output is (OK) initially • Becomes (NG) • No action taken by operator • Becomes (OK) • Use PM Analysis


OK

LSL

OK

USL

• The output is (NG) initially • Action taken by operator • Becomes (OK) (setting scrap) 10

TPM Club India


A - Type defect : Examples OK

NOT OK


LSL

OK

USL

11

KAIZEN - SHEET Brakes Division

JiPm -TPM

Category: A

B

C

Providing

Sub Comm

CU

Changing

Kaizen Theme & Target :

QM

Before improvement:

Year SL. No.

2000- 01 CU 128

Machine No :

To eliminate process scrap due to Damage of M133551 Crank shaft

Problem/Present Status :

Unit

EMA

Team MembersM . Karthikeyan Result / Benefit : Scrap due to wrong 4

loading 3

8

3

Q n o i t 2 c e j e R1

6 6

n o i t 4 c e j e R 2

4 3

0

0

Nov'00

Dec'00

Jan'01

Jan'01

Analysis :

After improvement:

Component damage – Induction hardng

Inductor hitting the component POKA YOKE

Component loaded in the wrong direction

Why

Reversible

Ir-reversible

If reversible updated in Operation Standard / QCPC JH Check Sheet PM Check Sheet Eqpt / fixture Drawing

Why

Why

Kaizen type

Feb'01

Scope & plan for Horizontal Deployment SLNo.

1

M/ M/cNo.

Target date

EMA

Mar’01

Resp.

MK

Status

Compld.

Possibility of wrong loading

Root Cause: Idea :

Possibility of Wrong Loading Prevent Possibility of Wrong Loading

Poka Yoke type & Function Prevention

Shut Down Control

KAIZEN - SHEET Category: A

Brakes Division

JiPm -TPM

B

C

Providing


Changing

Unit

Sub Comm

ACT

QM


Before improvement:

5

Result / Benefit : 5

4

4 4

y 3 t Q n j e 2 R

y 3 t Q n j e 2 R

2

2

2

1 1

0

0 Ju l y

Au g

S ep

Analysis :

Component damage during machining

Ju n e

After improvement:

Kaizen type

Ju l y

A ug

Sep

0

0

Oct

No v

Ir-reversible

Reversible

If reversible updated in Operation Standard / QCPC JH Check Sheet PM Check Sheet Eqpt / fixture Drawing

Why component pulled out Why Tennon broken Why weaker section of the tennon Why Reduced thickness Why to avoid fouling with jaws

Root Cause:

2

1

1

Idea :

032505

Team Members N.Kothandaraman

4

Ju n e

2000- 01 AU 087

Machine No :

Eliminate process scrap due to Component pull out in M270081 Cylinder in machine 032505

Year SL. No.

Scope & plan for Horizontal Deployment SLNo.

01

M/ M/cNo.

Target date

0325 032507 07

Oct, Oct,00 00

Resp.

NKN NKN

Status

comp comple lete ted d

Tennon fouling fouling with the jaws Poka Yoke type & Function

Avoid tennon fouling with jaws jaws

Prevention

Shut Down Control

Unit


JiPm -TPM

Category: A

B

C

Providing

Changing

Kaizen Theme & Target : Eliminate process scrap due to damage in Un loader valve before Apr’00

Problem/Present Status : Process scrap due to Damage

Before improvement: ULV Body Wrong Side on the top

4

Sub Comm

Year SL. No. 2000 2001

QM

V2

V2 025

Machine No :

082501

Team Members

BDN / TSS

Result / Benefit : 4 3

3 y t 2 Q

2

y t 2 Q

2 1

1 0 0 Jan '00

F eb

0 ' 0 n J a

M ar

Analysis : Damage in body Why ? Wrong loading of component

After improvement:

Why ? Fixture accepting wrong loading Why ? No stopper arrangement to avoid wrong loading

Root Cause: Idea :

Not able to load

Poka Yoke pin

a r M

b F e

Kaizen type

0

r y A p M a

0

0

l J u

n J u

Reversible

0

Ir-reversible

If reversible updated in Operation Standard / QCPC JH Check Sheet PM Check Sheet Eqpt / fixture Drawing Scope & plan for Horizontal Deployment SLNo.

1

M/ M/cNo.

Target date

086303

Aug’00

Resp.

Status

BDN completed

No stopper arrangement to avoid wrong loading Provide stopper to avoid wrong loading


Shut Down Control

TPM Club India


B - Type defect : Examples OK

NOT OK

No action by operator

LSL

OK

USL

15


JiPm -TPM

Category: A

B

C

Providing

Changing


Before improvement:


Process sequence

5 4

M ar

Ap r

M ay

4

0

0

M ay

Ju n e

Finish boring Ju ly

Finish boring operation done immediately after rough boring operation . . Process sequence

1 0

Back facing

After improvement: Process sequence Facing , OD Turning & grooving Rough boring

0

0

0

0

Aug

Sep

Oct

Nov

Kaizen type

Reversible

Ir-reversible

If reversible updated in Operation Standard / QCPC JH Check Sheet PM Check Sheet Eqpt / fixture Drawing Scope & plan for Horizontal Deployment

Why ?

Idea :

3 2

Rough finish on bore Analysis : Why ? Entrapment of Burr on bore during finish boring operation . Why ? Burr generated during Rough boring operation not fully flushed out

Root Cause:

Au- 072

5

1

0

Aug ‘ 99

Result / Benefit :

Rough boring

2 1

Year SL. No.

Team Members N.Kothandaraman

3

1

QM

Act

Facing , OD Turning & grooving

3

Sub Comm

Machine No : 032302

To reduce process process scrap scrap due to rough finish on Bore dia inM 272291 Ty 20 Ram

2

Unit

Back facing Finish boring

SLNo.

01

M/ M/cNo.

Target date

032304 Nov ‘ 99

Resp.

Status

NKN Completed

Presence of burr during boring operation Poka Yoke type & Function

To eliminate burr p resence

Prevention

Shut Down Control

Unit


JiPm -TPM

Category: A

B

C

Providing

To avoid the rejection in crank shaft due to tool digging mark

Machine No : Team Members

Before improvement:

Year SL. No. 2000 - 2001 CU -012

120802 M .Karthikeyan

Result / Benefit :

High rejection ,while running the crank shaft without the tailstocks Support

4

y 3 t Q n o i t 2 c e j e R 1

4

4

QM

cu

Before Mar’2000



Changing

Sub Comm

3 3

n o i t 2 c e j e R

1

1

0

0

Mar'00

Apr'00

0

0 Dec'99

Jan'00

Feb'00

Analysis : High rejection in 120802 Why Tool digging Why Excess Runout in the component Why Component not located properly Why No tailstock clamping

Root Cause: Idea :

Kaizen type

After improvement:

Reversible

Ir-reversible


1

M/ M/cNo.

120801

Target date

Jul’00

Resp.

MK

Status

Completed

Tailstock not clamping Poka Yoke type & Function

Eliminate tailstock not clamping

Prevention

Shut Down Control

TPM Club India


C - Type defect : Examples NOT OK


OK

LSL

OK

USL

18


JiPm -TPM

Category: A

B

Providing

C

Unit

Sub Comm

cu

QM

Changing


To reduce rejection due to Oil port spot face height undersize in TCL Crank case Zero by Apr’2001


Before improvement:

Year SL. No. 2000-2001 CU -185

Machine No :

087803

Team Members M .Karthikeyan Result / Benefit : 10

8

High process scrap due

Before

After

8

y t Q n 6 o i t c e j 4 e R

to oil port spot face height undersize in M 134561 TCL crankcase

6 4

2

0 0

Ja Jan n'01 '01

Analysis :

Oil port Spot face height undersize Why? More material removed removed on face Why? Tool length set excess

12.5

Why? No Setting facility How? Provide Setting facility

Root Cause: Idea :

Kaizen type

After improvement:

Feb' Feb'0 01

Mar'0 ar'01 1

Reversible

Apr'0 pr'01 1

Ir-reversible

Setting Master If reversible updated in Operation Standard / QCPC JH Check Sheet PM Check Sheet Eqpt / fixture Drawing Scope & plan for Horizontal Deployment SLNo.

1

M/ M/cNo.

086301

Target date

Jun’01

Resp.

MK

Status

Compl.

Tool length set excess Set the tool correctly


Shut Down Control


JiPm -TPM

Category: A

B

C

Providing

Unit

Sub Comm

v1

QM

Changing

Kaizen Theme & Target Eliminate : scrap due to Inner dia. O/S in

50 40

Multi rotational dial gauge Before improvement:

Team Members VT / RBS 50 Result / Benefit :

34 28

10

1

30

40 Qt 30 y 20

2

9

3

8

4

1 7

2 6

Big dial

5

20 0

10 Nov

Dec

34 28

0

10

Small dial

0

Nov

Jan’01 Feb

Analysis :

Kaizen type

After improvement: one rotational dial gauge

Dia 140.9 / 105.10 Bore over size 3

Wrong Setting by operator

4

5

2

6

1

7

Wrong reading of the dial Multi rotational dial

Root Cause: Multi rotational dial gauge used for measurement

0

0

Dec Jan’01Fe 1Feb’01Mar’0 r’01 Month Reversible

Ir-reversible


multi rotational gauge IdeaEliminate :

2000-2001 v1 -168

Machine No : 032601

R6 / RE6 top cover. Zero & Before March’01


Year SL. No.

M/ M/cNo.

Target date

Resp.

Status

1

032504 Apr’01

NKN

Compl.

2

032602 Apr’01

RBS

Compl.

3

032201 Apr’01

NKN

Compl.


Shut Down Control

TPM Club India


Setting of standard values for inspection items and confirmation of results If standard values are set for individual inspection items, and equipment precision is maintained within the standard range, it is necessary to confirm that all quality characteristics can be satisfied.

If they cannot, the cause is either that "there are omission in inspection items" or "Standard values are not stringent enough." In either case, it is necessary to return to PM analysis and carry out study. 21

TPM Club India


Concentration of inspection items and shortening of inspection time For orderly implementation of condition control, review inspection items themselves and satisfy the following conditions: • • •

Reducing inspection items by concentrating on the number of items for inspection Extending inspection interval by eliminating forced machine deterioration Shortening inspection time by taking steps for 'difficult to inspect' spots

If inspection items are many, inspection intervals are short, or inspection requires much time, maintenance and control will become difficult, and eventually achievement level will decline. Elimination of forced deterioration and spots that are difficult to inspect depends greatly on Jishu-Hozen implementation. 22

TPM Club India


Drafting of QM (Quality Maintenance) matrix and reflection in standards QA Matrix is prepared to establish the relationship between defect / defect mode and the process which causes it. It requires data collection for defects at various process stages to prepare a QA Matrix.

23

TPM Club India


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TPM Club India


25

TPM Club India


3M condition analysis. analysis. Please follow following guidelines. 1

Base Based d on on QD QD mat matri rix x iden identi tify fy wher where e the the defe defect ct is gen gener erat ated ed

2

Draw Draw a C & E diag diagra ram m for for the the def defec ectt for for each each proce process/ ss/su subb-pr proc oces ess, s,

3

Iden Identi tify fy inp input uts s for for eac each h M (Ma (Man, n, Met Metho hod, d, Mac Machi hine ne and and Mat Mater eria iall

4

Chec Check k each each inp input ut whe wheth ther er Stan Standa dard rd exis exists ts or or not. not. If If not not then then mak make e a sta stand ndar ard. d.

5

All standards are to be followed during Process.

6

If a standa standard rd is diffi difficult cult to follo follow w or or if they they are are loose loose then then stand standar ards ds are are to be revised revised..

Status of Standard Symbol 1 Loose Standard 2 No Standard 3As per standard and followed 4 Difficult to follow 5 Not followed 26

TPM Club India


27

TPM Club India


28

TPM Club India


QM Master plan Master Plan for quality maintenance is planning of various activities in this pillar with respect to the time frame in months and years. According to the stage of TPM implementation it can start at various levels. In the beginning it will start with data collection on defects to improving conditions conditions to sustaining zero defect conditions. 29

5 Quality Maintenence

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