Jishu Jishu Hozen Hozen Activitie Activities s Jishu Hozen Steps Step 1 - Initial Cleaning Step 5 – Autonomous Inspection Step 2 – Countermeasures against Sources of contamination Step 6 – Standardization & Hard to access areas Step 3 – Preparing tentative standards Step 7 – Autonomous Management Step 4 - General inspection Step 1 2 3 one set of steps. From step 4, quantum jump in level. After thorough step 4, go to step 5. Otherwise you falter in step 5. Implementation of Step 1 in part 1 All Product units started Jishu Hozen step 1 activity. Kobetsu Kaizen sub committee classified machines into “A, B & C” rank. Jishu Hozen sub committee concentrated on “A” rank and few “B” rank machines for break down, defect, accident reduction & to increase the availability and reduce cost. Team of workmen and officers were involved in the initial cleaning. During cleaning, abnormalities were identified & tags were attached. Tags were classified into red & white, red tags are removed by the plant maintenance & white tags were rectified by Jishu Hozen team members.
Cleaning of Ma chine by tea tea m Ta g Id entifica entifica tion tion Classification of tags in Red & White
STEP 1 Prep Prep a re Ta g ma trix trix Id entifica entifica tion tion of sourc ourc e of conti co ntimi mina na tion tion Identif Iden tifica ica tion of Diff Difficu icult lt to CL C LI Step 1 implementation
Implementation of Step 2 in part 1 Red and white white fuguai fuguai were were remove removed d in Jishu Jishu Hozen Hozen Step2. Step2. Counte Counterme rmeasu asures res were were taken taken agains againstt the source sourcess of contamination by providing localized guards, arresting leakages and horizontally deployed in all other areas. Countermeasures were taken against difficult to clean, lubricate and inspection areas, thus the Jishu Hozen activity time for cleaning, lubrication and inspection is reduced and machines remains clean without cleaning. C o untermea untermea sures ures aga ag a ins inst fugua is
STEP 2
C ountermeasur ountermeasures es ag a inst so so urce urce o f co ntamination ntam ination C o untermea untermea sures ures ag a inst ha rd to a cc ess ess a rea s for C LI
Implementation of Step 3 in part 1
Step 2 Implementation
Tentative standards were prepared for Cleaning, Inspection & Lubrication. Following colour codes & symbols were developed for carrying out the activity & indicating its frequency. C reate ea te tentative sta standa nda rds for C LI Route ma p ma rking king a round the ma chine chine
STEP 3 Prepa Prepa ra tion o f C LI check sheet sheet Implementation of visuals
Step 3 Implementation Figure 5.3 Step 1 implementation
Standard colour code symbols. ACTIVITY
DAILY
WEEKLY
MONTHL
Q UA R T E R L
CLEANIN (BLACK)
Visuals are implemented on the machines for ease of inspection like marking of lubrication / hydraulic oil level, motor RPM direction, belt direction, oil tank colour coding, pipe line colour coding.
INSPECTION (ORANGE)
LUBRICATIO (BROWN)
Activities under Part 2 To restore JISHU HOZEN activity, we developed ‘Dry Floor Steps 1, 2 & 3’ apart from the regular JIPM Steps.
Basic A pproac h not Co nsolida ted A ct ivities restrict ed t o only select ed manufact uring areas
STEP 7
Cha nge visible on Equipment but no c hange in people STEP 6 STEP 5 STEP 4
DRY FLOOR STEP 3
Ac tivities with Empha sis on
STEP 3
funda mentals for a
DRY FLOO R STEP 2
Reversal
strong founda tion STEP 2
DRY FLOO R STEP 1
STEP 1
PART1
PART2
Jishu Hozen steps
Wider implementation Machines = 406, Operators = 1020 Assy stages = 0, Support function = Jishu Hozen circles = 0 0
A Rank M/C 100 %
A Rank M/C 100 %
Operators
B Rank M/C 60%
55%
PART- 1 JISHU HOZEN ACTIVITIES CO VERAGE
Stores 0%
Maintenance 0% Inspection Area 0%
Machines = 646, Operators = 1986 Assy stages =39, Support function = 19 Jishu Hozen circles = 161
C Rank 30 M/C
Assembly Area 0%
B Rank M/C 100 %
Operators 100 %
Stores 100 %
PART- 2 JISHUHOZEN ACTIVITIES COVERAGE
Maintenance 100 %
Wider implementation of Jishu Hozen
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C Rank M/C 100%
Assembly Area 100 % Inspection Area 100 %
Focus on Circle up gradation concept
MY CIRCLE CONCEPT
MY MACHINE CONCEPT
Activity Board
Circle Meetin
Jishu Hozen concept
Organization Chart & Circle formation All equipment & all people are involved. Each circle was allocated multiple numbers of equipments. TPM organization was formed consisting of Plant head, Unit heads, Product unit heads, and Module managers, Officers and Operators.
V. P. Manufac turing
Plant Head
Axle PU
QA
Body PU
Engine PU
Maintene
Manufact
nce
uring
C ell 1
C ell 2
C ell 3
Foundry PU
Assemb ly
TMPU
Stores
C ell 4
Circle 1 Circle 2 Circle 3 Circle 4 Circle 5 C irc le 6
Vehicle PU
PU Manager
Module Manager
Cell Leader
Circle Leaders
Organization Chart & Circle Formation
TPM is a system of overlapping circles. Equipment approach is not wrong. But equipment does not change on
its own. It is the organization that owns it. While forming the circle please keep organization in mind. Each circle ideally should contain 8 to 10 persons. Purpose is to groom the circle leader to do the work. No of equipment & No of persons should be balanced. In a circle you have circle leader and member.
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Implementation of Dry floor steps at manufacturing shop D ry floo r pl
D ry f lo o r sh
C irc le m e e i A c tiv it y b o
D ry flo o r st
D ry flo o r st
C la ssific a i 5 DO N ' o f 7 typ tags
O P L'S
Manag round
Sources c o n ta m i
L ei a k a g
on
D ry flo o r st
E a sy t o acces
Te n t a t iv st a n d a rd C IL
Capturi t h e lo ss
V i su a ls
Concept of Dry floor steps
Activities for Dry Floor Step 1: Re- Initial Cleaning (IC) It is not just cleaning. We say cleaning is inspection. Cleaning time becomes zero only when your sources of contamination becomes zero. IC means restoration of ignored equipment to bring to original condition. Your machine needs initial cleaning. Continue cleaning till sources of contamination become zero. IC is to find fuguai a) Functional cleaning - superficial cleaning no good. Only functional cleaning of the equipment helps in finding out fuguai. I do not want spic & span equipment. Ideally yes. Purpose is functional cleaning. When you do the manager model, uniform tells the story. Initially everyday m/c becomes dirty after cleaning of previous day. That takes you to step 2. You must do something. b) Identification of sources of contamination & hard to access areas – this has to be done hard way, not by observation but by having folded arms. Ideas come when you get involved. So this is very important. Link with step 2. Textbook says source of contamination in step 2, but step 1 leads to step 2. More effort in step 1, better the step 2. In JH stagnation comes if step 1 not thorough. Only with supervisors u can not change shop floor. JH circle need to be functional In Dry floor step 1 additional activities like daily manager round & 5 DON’T’S activities were introduced to strengthen the Jishu Hozen circle activities. Fuguai classification is done to prioritize the fuguai removal.
5 Don’t on the Shop Floor: 1. 2. 3. 4.
Don’t keep -Material/Jigs/ Tools/Measuring Instruments/Products directly on the shop floor/equipment. Don’t keep Material/Jigs/ Tools/Measuring Instruments/Products directly on the shop floor. Don’t write directly on machines/walls/doors etc. Don’t stick things directly on machines/walls/doors etc.
5. Don’t take the temporary countermeasures
2 Do’s on the Shop Floor: Vicinity of Equipment: 1) Fix position
2) Fix quantity
Excess must go out (Tools/Jigs/Material/Products/WIP)
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Equipment Initial Cleaning
DryFloorStep 1
Daily Manager Round
Fuguai Identification
5 Don’t's
Fuguai Classification
Fuguai Rectification
Machine, .Walls & Doors
Fuguai Classification 1) Unsafe places 2) Unwanted / Slow moving 3) Quality defect 4) Hard to access 5) Sourcesof Contamination 6) Basic Condition
4) Don't stick things directly
7) Minor defects.
5Don’t's 1) Don't keep Material on Shop Floor 2) Don’t Keep Material randmoly. 3) Don't write directly on
on .Machine ,Walls & Doors 5) Don't take temporary counter .... .measures.
Dry floor step 1 implementation
Fuguai classification & Approach towards fuguai In Phase-II fuguai classification was done as follows for prioritizing the fuguai removal. (Meant for JH circles – teach them)
Fo un d
Re ctif ied Minor Defect
Basic Condition
Source of Contaminat ion
Hard to Access
Quality Defect
Unnecessar y
Unsafe Point
How to identify which type of fuguai is it? For this you always start from the right hand side as shown by the arrow. Let’s consider the example of screw missing at any point. By considering this you just think, can the screw missing cause unsafe condition? If the answer from this is yes than this fuguai belongs to unsafe point other wise ask the same question for unnecessary items. Is the missing screw unnecessary? If the answer is yes then classify the abnormality (Fuguai) in Unnecessary other wise ask the question -Is the missing screw causing quality defect? If the answer is yes then categorize it as quality defect other wise ask the next question. Same for other types also. Suppose nut / bolt loose – you think deviation from basic condition. Don’t do that. Start from RHS. If any safety hazard due to loosening, it will fall under safety point. It may also fall under unwanted/unnecessary. Then remove.
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If there is some quality problem, it could be under quality defect. It was loose because it was hard to access. Suppose chips falling due to loosening then source of contamination. If it falls under one condition, stop. If it does not fall under any of six condition then under minor defect. Bolt/nut generally basic condition.
One Point Lessons One Point Lessons are imparted to JISHU HOZEN Circle members for - Basic Knowledge: Points that must be known - Improvement Cases: Point that prevents the recurrence of troubles
- Trouble Cases : Points of improvement concept / method leading to positive results OnePointL esson
Basic Knowledge
Trouble Cases
Improvement Cases
One point Lesson
Activities for Dry floor Step 2: Kaizen/Countermeasures for contamination/Leak free & Easy to access equipment Reduction of C L I time is key parameter. Sum up these through Kaizen example sheet / OPL (generated thru CLI reduction) Normally machine cleaning of 15 hours/man/month is required. Only then machine changes. Particularly for manager model. If manager model > 20 hours but no perceptible change then they are losing time somewhere. Some team good change in 10 hours. Learn from them. For step 3, less time required. Fuguai removal is done as per the priority of Fuguai classification. To achieve & sustain leakage free equipment, the following approach is used: DryFloorStep2
Contamination Free Equipment
Reduction of Contaminant Generation
Leakage Free Equipment
Provision of Localising the
Elimination of
Guardsto arrest
Contaminant
Contaminants
splashesof Oil & Coolant
Modification of Pressure/Directio n of Oil/Coolant
Conversion of Flexible Hosesto Permanent MetallicPipes
Difficult to Acc ess
Modification of Relocation of
Rerouting of
guards,
element
pipes / cables
platforms& ladders
Dry floor step 2 approach
(I)Arresting Sources of Contamination Sources of Contamination: Chips, Oil, Sand, Dust, Coolant, Humidity, Noise, fumes/ smoke, sputters, water/air leakage, spray, oil soaked water, paint sludge, steam, people etc. Identify all sources of contamination. Even the product can be a source of contamination. In sugar factory sugar itself can be a contaminant. Dropping of product should not happen.
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Kobetsu Kaizen teams consisting of manufacturing, improvement cell, maintenance were formed to help Jishu Hozen to eliminate Source of contamination. Countermeasures against source of contaminations were taken by applying the methodology to contain the source of contamination. Can I eliminate the source?
Oil leakage- in principle- eliminate it. If not possible (rare), minimize it wherever it involves high cost.
Minimize
Collec
Collection – If leakage from top, put it close to source. Don’t come straight to collection. Don’t provide huge collection pan. Put a visual control mark.
Localize
Methodology to contain the source of contamination Put S No. Empty it every day
If you do that, you’ll know lesser or more than previous day. Then why why. I saw very big collection pan & almost full. That will not do. Follow this approach. Put S. no. EMPTY IT
Contaminants EVERY DAY wise action plan was prepared to arrest the source of contamination Sourc e o f co ntam ination reduc
Chips
Reductio in machinin stock
Use of loc a lised guards
Sa nd
Oil / C oolant
Design change
Provision
Use o f
loc a lised
collectio
guards
tra ys
Process
Collectio
Reductio
of c hips b
of chip siz
using tra y
by cuttin
chutes,
tool a ngl
to d ry
O p timisa t on of direction p ressure
Provision skirting o conveyo
Use of
Sea ling o
Use o f du
conveyo
gua rd s a
opening
extractio
be lt widt
d isch a rg
in sand
end of
conveyin
system a t increase generatio
to 800 m
Provision
Optimisat
Wo rn out
change
on of
d ie surfa c
trollies to
from w et
coolant
reconditi
collect
flow
ning
sp illed
Actions for source of contamination
(II) Leakage Free Equipment To achieve the leakage free equipment Elimination, Minimization, Localization of the contaminant was done. Leakage Free Equipment
Conversion of
Provision of
Modification of
Flexible Hoses to
Gua rds to arrest
Pressure/ Directio n
Permanent
spla shes of O il &
of Oil/Coolant
Metallic Pipes
Coolant
Hose p ipes
Use o f sea lants
Reduction of
Relocation of
Relocation of
Optimisation of Use of loc alised
rerouting with
for fittings
extra length
coolant,
oil / lubrica nt
pressure of oil /
pipes
lubricant tanks
nozzles
lubricants
rigd c lamping
guards
Actions for leakage free equipments
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Use of guards
Use of guards
with collection
with c ollecting
trays
ducts
III. Activities for Hard to Access area Hard to Access Areas means : Difficult to lubricate Difficult to inspect Difficult to clean Difficult to retighten Difficult to operate JH is not only for maintenance of machine but also for operation of it. Even set up /adjustment comes under it. Counter measures against Hard to access areas for cleaning, Lubrication, Inspection and retightening are Identified and Rectified.
Hard to a c ce ss
Easy to access for cleaning
Re routing of pipes / cables
Modificatio n of platforms
Use of plain conduit inplace of spiral
Esay to access for Inspection
Removal of unwanted / big guards
Relocation of gauges
Provision of ladders / stair case
Implementa tion of visuals
Relocation of lubricating units
Easy to access for Lubrication
Relocation of lubricating units
Rerouting of pipping
Modification of filling caps
Activities for Dry Floor Step 3 – Preparing Tentative Standards for Contaminant/Leakage free equipment With the help of Planned Maintenance & Machine manuals, Tentative Cleaning, Lubrication and Inspection Tentative Standars standards, check-sheets & route maps are developed by operators for daily Cleaning, Lubrication, Inspection & re-tightening. Dry Floor Step 3
Route Map
CILCheck Sheet
H draulic
7
power pack
Visuals ForCLI Cleaning Daily
Situated on platform
4
Cleaning W eekly Cleaning Monthly
Inspection Weekly
5
Blow plate
Inspection Daily
Machine column Hydraul ic valve
3
6
Inspection Monthly Lubrica tion Daily Lubrication Weekly Lubrication Monthly Cleaning 1.Tentative standard 2.Check sheet 3.Route map
Left hand
Lubrication part
Right hand part
Inspection
2 Electr ical contr ol panel
1
For each of these (C L I) a set of three required.
Dry floor Step 3 implementation
8
You don’t carry standard all the time. Standard is for understanding. Check sheet is for filling up.
Step 3 also visual Control. If
oil level green, ok but if always in green, same level, then not ok.
It
must go down otherwise it is not functioning. R G R
When you teach operators to see oil level, tell them to monitor if it is going down or not. Only mechanical checking will not do. Visual control help you to certain extent but you need to bring ingenious ideas in that.
If fan is moving or not seeing that is enough. Go a step further, ball, how high it is flying, whether flow enough. Do such ingenious ideas. This reflects on your activity. paper
Fan
Education on General Loss is generated when equipment stops for less than 15 minutes & machine component is not replaced. Inspection Capturing Minor Stoppages, incidents have beenLeaders done by the JISHU HOZEN Circle members to improve performance
Minor Stoppages rating & OEE.
Counter Measures are taken by the JISHU HOZEN circle members to reduce Minor Stoppages. NG Understanding Step 4 activities – General Inspection
thru test In step 4 we aim to understand the structure, functions & principles of the equipment & to study its ideal state, to seek the
ok
utmost improvement in the efficiency of equipment. Aim to inspect all constituent mechanisms & parts of the equipment, Leader towith Circle without exception, with the eye of an “operator skillful equipment”. In training modules are prepared to enhance the member
skill & knowledge of circle members. There are 6 sub steps: 4.1 Nut & Bolt
General Inspection
4.2 Drives 4.3 Lubrication 4.4 Pneumatics
Rectification/ Kaizen for fuguais
New things will get added. Make 4.6 Electrical & Electronics correction in hand. The sequence is important. There are 2 parts of step 4 for implementations as
4.5 Hydraulics
shown here.
Revision of Std/ check sheet.
Summary
These training manuals will be created by E & T. Actual implementation by JH. Thus 2 pillars are involved
Self Audit (90%).
Methodology of step 4 implementation Manual
Education on General Inspection
Manager Audit (85%)
Top Mgt. Audit (80%)
Next Sub Step9
Actual Implementation of General Inspection
Teach what kind of fuguais can be present. Set of OPLs required. Summary of Results: e.g. How many nuts and bolts together for inspection? How many fuguais identified. Categorize them e.g. Nuts and bolts rusty, without washer, missing etc and review tentative standards created so far. Use red colour for wrong check point. Include new items in red. Remove / cross points as applicable. In step 5 these standards get converted into final standard. Most important are tentative standard and check sheet. After education & training ,further changes are required. Content wise step 4 fuguai has to be much deeper. In step 4 many many new fuguai will come to light. Till step 3 emphasis was on 5 senses and not on education & training. Now education & training and review of standards / check-sheets / route-maps and the same need to be updated in step 4. It is a good idea to plot the number of corrected standards (C L I ) against sub steps of step 4.
Step 5: You have tentative standard + check sheet + maps corrected in step 4. In step 5, Combined final standard as against one standard/check sheet/route map for each of C L I.
JH Implementation at Assembly line Step 1 Activities -Initial Cleaning
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Removal of waste,stain marks & dust Arrangement of shelves, boxes,work table, tools & Jigs Identification & removal of unwanted & slowmoving objects STEP 1 Provision of area for non confirming parts Implementation of displays Identification & rectification of fuguais
Assy Step 1 implementation
During initial cleaning waste, stain marks & dust are removed. Arrangement of Shelves, boxes, worktables, tools & Jigs are done. Fuguai’s were identified and rectified.Slow moving, unwanted objects are identified and removed from the area. Storage place for non confirmative parts are provided. Visual controls are implemented.
Step 2 Activities - Countermeasures against Sources of Contamination & Difficult to access C ountermeasures ag ainst bending , stretching & turning C ountermeasures for moving heavy objects Eliminate double handling & inspection of parts STEP 2
Counter measures are taken against sources of contamination, for moving heavy objects, for elimination of operations
involving
bending,
stretching, and turning of body & to reduce the time required for counting
First in first out for parts Poka Yoke to reduce defects Reduce time required for co unting of parts Storage place for removed packing materials
parts. Placement of tools in such a way that double handling/Inspection eliminated by introduction of easy to pick tools, ease of use of Jigs, Tools. First In First Out for parts is started.
Assy Step 2 implementation
Step 3 Activities – Creation of Tentative standards
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Tentative standards for C IL C IL time reduction Implementation of Visual C ontrols STEP 3 Eliminintation of counting, searching, confirmation of parts by visual Review of work standards Review of setup & adjustement
Assy Step 3 implementation
Thrust given on implementation of cleaning, Inspection & Lubrication standards, and Visual controls implementation on assembly stages .By implementation of visual controls non value added activities like searching, counting & confirmation of
parts were eliminated. Reduction of losses like set up & adjustment is carried out.
STEP – 4: General Inspection 4-1 : Jigs & Tools used in Assembly 4-2 : Measuring Instruments 4-3 : Online Inspection 4-4 : Devices used in Assembly Line 4-5 : Operability / Sustainability
STEP – 5: Line Balancing STEP – 6: Autonomous Control
3 treasures of JH: 1. Meeting 2. Activity board 3. OPL
JISHU HOZEN CIRCLE ACTIVITY STATUS Unit
Axl e PU
Cell
Pinio n Cell
Circl e Nam e
Dry Floor Plant Step 1
Ste p2
Ste p3
Ste p1
Ste p2
Ste p3
Step 4 4.1
4.2
4.3
4.4
4. 5
4. 6
Ste p5
Date of passi ng
One circle in charge of multiple machines. Criteria for passing some machine –individual audit- when all equipments pass, circle passes.
Data Required for JH: 1. Activity Time on JH Circles. TOTAL Activity TIME. • Activity Time per person(Avg.) •
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By Experience, 15 hours/person /month required. change comes visible. Distribution of time is also important. 20 minutes are not enough for functional cleaning. Additional cleaning say 2 Hrs at a time required for thorough Cleaning. 20 minutes they may or may not work. 2hrsx 3, 4hrs× 1, you can have for concentrated JH in addition to daily 20 minutes. 2. No. of Fuguais DETECTED & RESOLVED 7 Classification of Fuguais • RED & WHITE tags. • Conversion of RED to WHITE TAGS 3. Sources of Contamination 4. OEE Data (compilation by KK) Loss DATA • Minor stoppage • 5. One Point LESSON SHEETS 6. No. OF KAIZEN EXAMPLE SHEETS
7. No. of DI FFICULT to ACCESS AREAS DETECTED & RESOLVED.
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