8 Pillars of TPM e c n a n e t in a M s u o m o n o t u A
t n e m e v ro p m I d e s s u c o F
e c n a n te n i a M d e n n a l P
e c n a n e t n i a M y ti l a u Q
t n e m e g a n a M t n e m p o l e v e D
g n i n i ra T
& n o it a c u d E
t n e m n o ri n v E & h tl a e H , y t e f a S
e c fi O n i M P T
Autonomous Maintenance Autonomous Maintenance is the activities in which each worker performs daily inspection, lubrication, parts replacement, minor repair, trouble shooting, accuracy checks etc. on his own equipment, aiming at achieving the goal of “Keeping one’s own equipment in good condition by oneself ”
The Mind set ……….. Individual preserving one’s own equipment Significant change from early theory of “ I manufacture –
You repair”
or
PRODUCTION • Maintenance does not its job • They take too long to fix the equipment • This equipment is so old no wonder it breaks down again and again • We are too busy to do vital daily checks
“I make - You Fix”
MAINTENANCE • Production do not know how to operate • We get lot of repairs so we don’t have ample time to do a real corrective action and are forced to do only temporary job •We prepare the standards but they do not do the checks
Operators for Skill and Knowledge
DEVELOP
of his equipment To do Jishu Hozen on his equipment
Operator/Supervisor/
Responsible
What TO DO
Officer/Manager 1. Initial Clean Up 2. Countermeasures for Contamination Sources & Hard to do CLIT 3. Apply Tentative Standards 4. Carry Out General Inspection 5. Do General Process Inspection 6. Standardize the Activities 7. Improve & Maintain
HEINRICH TRIANGLE Major Problem (1)
Medium Problems (29)
Minor Problems (300)
Invisible Problems (3000)
EQUIPMENT DETERIORATION Natural Deterioration Accelerated Deterioration Extend Life Time
Corrective Maintenance • Prevent errors by improving operability •Improve Maintainability & Repair Quality • Improve safety & Reliability
Eliminate Causes
Establish Condition • CleaningBasic : Eliminate all dust & Dirt • Lubricating : Keep lubricants clean and replenished • Tightening : Keep nuts & bolts secure
• TO PREVENT EQUIPMENT FORCED DETERIORATION • TO MAINTAIN EQUIPMENT IN OPTIMAL CONDTION • TO ESTABLISH BASIC EQUIPMENT CONDITION • TO ELIMINATE EQUIPMENT FAILURE • TO MAKE OPERATOR EQUIPMENT COMPETENT • TO ELIMINATE QUALITY DEFECTS • TO ELIMINATE COST LOSSES
Concept of “Jishu Hozen” Cleaning is Inspection Inspection is a step to find “Fuguai” (abnormality) “Fuguai” should & could be restored or improved Restoration & Kaizen are a kind of Success Success is a pleasure as a result of achievement
It enhances ability to find & improve “fuguai” It changes the mindset of people
AUTONOMOUS MAINTENANCE STOP ACCELERATED DETERIORATION CLEAN THE EQUIPMENT IDENTIFY PROBLEM AREAS AND RECTIFY DEVELOP/IMPLEMENT STANDARDS
BRING IT BACK TO ORIGINAL STATE DO IMPROVEMENTS IDENTIFY AND ELIMINATE CHRONIC PROBLEMS AND HARD TO ACCESS AREAS DEVELOP/IMPLEMENT STANDARDS
IMPROVE IT FURTHER KNOW YOUR MACHINE WELL INNOVATE AND IMPLEMENT NEW IDEAS
7 Steps of Autonomous Maintenance Autonomous Management Standardization Autonomous Inspection General Inspection Preparing Tentative Cleaning, Lubrication, Inspection & Retightening Stds. Countermeasures against Sources of contamination & Hard to Access areas
Initial thorough Cleaning
Preparation
Familiarization with the equipment and its current condition “1S/2S” activities on and around the equipment Understanding Forced Deterioration & Need for Autonomous Maint.
Understanding Equipment (Simple illustrations of the Equipment) Safety (listing of all unsafe conditions & safety training)
Skill Needs for Initial Cleaning & finding abnormalities (Step-1)
Past Problems of the equipment (failures, defects, complaints etc.)/OEE Preparation of TPM Circle Activity Board
5S SEIRI
SORTING
SEITION
SYSTEMATISING
SEISO
SHINING (Cleaning)
SEIKETSU
STANDARDISING
SITSUKE
SELF-DESCIPLINE
SAMPLE
Line Diagram showing Dirt/leakage map TO COOLING TOWER
SERVICE WATER LINE F.W.PUMP
DELIVERY VALVE N. R .V
DELIVERY VALVE
ICW LINE V.T. PUMP F.W.PUMP DELIVERY HEADER
SCALE PIT # 2 PUMP PIT
GREASE SPILLAGE WATER LEAKAGE OIL LEAKAGE
LISTING OF THE PAST PROBLEMS OF THE TPM CIRCLE SN
Problem description
Frequency
TotalTimeLost
STATUS OF THE SAFETY AND PROTECTIVE DEVICES Sl. No Name of the Safety/Protective Device
Present Status Checking Standard (OK/ Not OK)
Response (if not OK)
Target Date
MONITORING OF OEE OEE BaseLevel CurrentAvg. Target
33.60 59.65 93.10
100 90.0
75
65.0
50
25
r a M
n a J
l u J
y a M
v o N
p e S
Quality Rate
Performance Rate
Availability BaseLevel CurrentAvg. Target
60.00 80.75 95.00
BaseLevel CurrentAvg. Target
70.00 82.08 98.00
80.00 89.00 100.00 95.0
100
100
100.00
BaseLevel CurrentAvg. Target
90.0 81.0
75.00 75
70.0
75
50.00 50
50 25.00
0.00
an J
r a M
ay M
l Ju
25
25
ep S
v o N
n a J
r a M
y a M
l u J
p e S
v o N
n a J
r a M
y a M
l u J
p e S
v o N
Activitiy Board CircleNa m e : Team Memebrs:
LossStructure Results trend on V ari ous attributes of P, Q, C, D, S & M
Jishu Hozen summary of abnormalities & analysis 1. Red & whi te tag statu
s
2. Hum an Vs Equi pm ent weak nes s matrix
Equipment Schem atic Diagram
(Kobe tsu Ka ize n) Proce ss Theme s: Identified, Solved & Status
TPM Targets Jishu Hozen a nd Planne d P, Q, C, D, S, M Base values, Maintenanc e immediate plan for Benchmark & Targets next 3-4 months
Master Pla n (next 3-4 Years)
Audit Results: Jishu Hozen a nd Planne d Maintenance AuditDa te spla nne d: C, L, I, & R sta nda rds Summary of Why Why Analysis (caus e vs num ber o f an al ys is) ,
One Point Lessons (month vs Numbers) and Kaizens (m onth v s Numbers)
3. Ar ea-wise equi pm ent weakn ess 4. Abno rm al ity typ e wis e stat
Before a nd After Photographs Process Theme for the Month: Detailed action Plan with responsibilities One Point Le ssons Detailed Plan for the month of various pilla r a ctivities
Ka i z e n She e ts W hy W hy a na lysi sShe e ts Communication point: Mee ting Notice (Date, Ve nue, Agenda & Time) , Other communication between me mbers etc.
Example of Activities Board Leader Sub leader
Members
Circle
Section and Subsection Policies Goals and Measures
Kobetsu-Kaizen
Themes !
Reason for Selection
Understand Present status
Analysis
Troubleshooting and Schedule
Jishu-Hozen Activity schedule
Accomplishment Indices Overall Efficiency
* Fuguai List One-Point Lesson
Performance Rate
Availability
Non Defective Rate
Effect
Prevention of Recurrence, Remaining problems
List of Doubts
“Good to Find” Corner
Photo e c n ta p e c c A
e r liu a F
d e e p S
r o n i M
e g a p p o t S
t c e f e D
Before
k r o
w e R
Number of Suggestions
Efu Attaching and Removing
Actual Work
Meetings Activities
Before
One Point L esson TPM Circle Prepared by:
Sl. No.
Preparation Date
Theme
Classification ( W hich ever is applicable)
Basic Condition Trouble Case Improvement Case
W hat Condition is Abnormal
Why the condition is Abnormal
W hat will happen if continuously used without correcting Abnormality Troubleshooting
Date Executed Teacher Student
TPM Circle Details Department :
Cold Rolling Mill
TPM Circle :
PLTCM Welder
Team Details Mr. Mr. Mr. Mr. Mr. Mr.
A Chakraborti A Behera A Chadnani K Kant J Sinha P Kumar
Circle Meeting
Facilitator Leader Member Member Member Member
: Every Monday 3 PM
MASTERPLAN TPCMiPrcL:leTCWMELD(ECRRM)
sample
M ONT H 1S/2S ACTIVITY & VISUAL MANAGEMENT JISHU HOZEN JH STEP ZERO JH STEP ONE JH ST EP ONE AUDIT JH STEP TWO JH STE P T WO AUDIT JH STEP THREE JH STE P T HREE AUDIT
AprM ay Jun Jul AugS ep Oct Nov Dec
Jishu Hozen Step - 0 Activities Performed
Present Status
Jishu Hozen training imparted
Completed
Understanding the equipment (sketch/line diagram of machine)
Completed
Safety related training imparted
Completed
“1S/2S” activities on the machine
*
Under Progress
Historical data of the machine (Failures (freq./duration),defects etc.
Under Progress *
Activity Board Maintenance
Yes
* Show the line diagram/historical data on next slides
7 Steps of Autonomous Maintenance Autonomous Management Standardization Autonomous Inspection General Inspection Preparing Tentative Cleaning, Lubrication, Inspection & Retightening Stds. Countermeasures against Sources of contamination & Hard to Access areas
Initial thorough Cleaning
Preparation
Cleaning & Inspection to Expose Abnormalities • Follow Safety Instructions • Open Cover (do not dismantle) for Cleaning • Touch and Clean every Corner • Clean not only Equipment but also accessories • Cleaning is for Inspection • Find Abnormalities and Faulty Places • Attach tags (Red / White) to abnormalities identified • Restore abnormalities on the spot whichever are possible • Analyze abnormalities for root causes & develop countermeasures (Kaizens)
• Remove tags if abnormalities are restored.
Cleaning consists of removing old dust, dirt, grime, oil, grease and other contaminants that adhere to equipment and accessories , in order to find fuguais (abnormalities) and expose defects.
Responsibility Allocation & Drawing Schedule Provide Basic Training to Initiate Step-1 Allocating places for cleaning (Equipment + Accessories) to all members, based on their skill.
Detailed Cleaning Plan (Map)
Leader to explain plan to all members Schedule for all places given to members Adjusting schedule for other works.
Month `Name Day 1 AA BB CC
Day 2
Day 3
JISHU-HOZEN PLANNING SHEET FOR STEP-1 CLEANING TPM Circle/ Equipment Name: Equipment Parts Sub-Assemblies
Man-hour Members needed 1
Month: 2
Legend:
3
4
5
6
7
8
9
10 11 12 13 1 4 15 1 6 17 18 1 9 20 2 1 22 23 24 25 2 6 27 2 8 29 30 31
NM ao m efm e bers: 1.
Planning 2.
Cleaning & Fuguai Identification
3.
Summerization
4.
Analysis & Identifying Countermeasures
5.
Implementing Countermeasures
6.
Shutdown Dates Format: 3.2
JISHU HOZEN PLANNING SHEET FOR STEP -1 CLEANING Equipment: Laying Head Assembly
Components
Motors & Couplings
Members
30 31 1
2
3
4
5
6
7
8
Month: April 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
B. C. Sadhukhan R. L. Dubey B. Debraj
Gear Box
H. K. Chaturvedi Daljeet Singh
Gear Assembly Hood & Trippe
Mohan Singh
plate M. M. Sridhar
Hydraulic system
G. S. Chatterjee
L e g en d :
M embers: Mohan Singh
Planning
B. C. Sadhukhan R. L. Dubey
Cleaning & Fuguai Identification Summerization Analysis & Identifying Countermeasures Implementing Countermeasures
B. Debraj H. K. Chaturvedi Daljeet Singh M. M. Sridhar G. S. Chatterjee
Shutdown Dates
CLASSIFICATION OF FUGUAIS Equipment Weakness
Human Weakness
1.Minor Flaws
1. Non Observance of Basic Condition
2.Unfulfilled Basic conditions
2. Non Observance of Used 3.Sources of Contaminations 4.Hard to Access areas
Condition
5. Quality Defets
3. Leaving deterioration unattended
6.Non urgent Items
4. Design W eakness
7.Unsafe places
5. Shortage of Skills
1.MINOR FLAWS 2. UNFULFILLED BASIC CONDITIONS 3. INACCESSIBLE PLACES 4. CONTAMINATION SOURCES 5. QUALITY DEFECT SOURCES 6. UNNECESSARY AND NON-URGENT ITEMS 7. UNSAFE PLACES
1.MINOR FLAWS : Contamination Dust, Dirt, powder, oil, grease, rust, paint Damage
Cracking, bending,
crushing,
deformation,
chipping,
Play
Shaking, falling out, tilting, eccentricity, wear,
Slackness
distortion, corrosion, Belts, Chains
Abnormal Phenomenon
Unusual noise, overheating, Vibration, strange smells, discoloration, incorrect pressure or current
Adhesion
Blocking, hardening, accumulation of debris, peeling, malfunction
2. UNFULFILLED BASIC CONDITIONS Lubrication
Insufficient, Dirty, Unidentified, unsuitable, Leaking
Lubrication
Dirty, damaged or deformed lubricant inlets,
Supply Oil level gauges
faulty lubricant pipes Dirty, Damaged, leaking, No indication of correct level
Tightening
Nuts and Bolts slackness, Missing, Crossthreaded, Too long, Crushed, Corroded, Unsuitable washers, wing nuts on backward
3. INACCESSABLE PLACES Cleaning
Machine construction, Covers, Layout, footholds, Space
Checking
Construction, Covers, Layout, footholds, Instrument position and Orientation, Operating – Range display
Lubricating Position of lubricant inlet, construction, height, footholds, lubricant outlets, space Tightening
Covers, Construction, Layout size, Space
Operation
Machine layout, Position of valves, Switches and levers, Footholds
Adjustment Position of pressure gauges, thermometers, flow meters, moisture gauges, vacuum gauges, etc.
4. CONTAMINATION SOURCES Product
Leaks, Spills, Spurts, Scattering, Overflow
Raw materials
Leaks, Spills, Spurts, Scattering, Overflow
Lubricants
Leaking, Spills, Seeping oils, Hydraulic fluids, Fuel oils, etc.
Gases
Leaking compressed air, gases, steam, vapors, exhaust fumes, etc.
Liquids
Leaking water, Hot, Cold, half finished products, Waste water, Leaking supply lines etc.
Scrap
Flashes, cuttings, packaging materials, and non conforming products.
Others
Contaminants by people & Forklifts, Infiltration through cracked walls, broken windows etc.
5. QUALITY DEFECT SOURCES Foreign Matter
Dust, Rust, powder, chips, moisture, wire scraps, wood pieces, paper pieces, stones etc.
Shock
Dropping, Jolting, collision, Vibration etc.
Moisture
Too little or Too much, infiltration
Grain Size
Abnormalities in screens, Compressed air separators, centrifugal separators,
Concentration
Inadequate warming, heating, compounding, mixing, evaporation, stirring etc.
Viscosity
Inadequate warming, heating, compounding, mixing, evaporation, stirring etc.
6. UNNECCERY AND NON-URGENT ITEMS Machinery
Pumps, fans, compressors, columns, tanks etc.
Piping equipment Pipes, hoses, ducts, valves, dampers etc.
Measuring instruments
Temperatures, pressure gauges, vacuum gauges, ammeters etc.
Electrical equipment
Wiring, piping, power leads, switches, plugs etc.
Jigs & Tools
General tools, cutting tools, jigs, molds, dies, frames etc.
Spare parts
Standby equipment, spares, permanent stocks, auxiliary materials, etc.
Makeshift repairs Tape. String, wire, metal plates etc.
7. UNSAFE PLACES Floors
Unevenness, cracked, holes, projections, peeling, wear of steel chucker plates, slipping.
Steps
Too steep, irregular, slipping, missing handrails, etc.
Lights
Dim, out of position, dirty or broken covers, no explosion proofing, etc.
Rotating machinery
Displaced, fallen oil or broken covers, not safe for emergency, missing emergency stop devices
Lifting Devices
Wires, hooks, brakes and other parts of cranes and hoists etc.
Others
Special substances, solvents, toxic gases, insulating materials, danger signs, protective clothing etc.
HARMFUL EFFECTS OF INADEQUATE CLEANING Failure
Dirt and foreign matter penetrates rotating parts, sliding parts, pneumatic and hydraulic systems, electrical control systems and sensors etc., causing loss of precision, malfunction and failure as a result of wear, blockage, frictional resistance, electrical faults etc.
Quality Defects
Quality Defects are caused either directly by contamination of the product with foreign matter or indirectly as a result of equipment malfunction.
Accelerated
Accumulated dust and grime make it difficult to find and rectify cracks, excessive play, insufficient lubricants, and other disorders, resulting in accelerated deterioration.
Deterioration Speed Losses
Dust and dirt increase wear and frictional resistance causing speed losses such as idling and under performance.
Checkpoints for Nuts & Bolts Slight defects
Loose nuts & bolts, missing nuts & bolts
Bolt length All bolts should protrude from nuts by 2-3 threads
Washers
•Are flat washers used on long holes •Are tapered washers used on angle bars & channels •Are spring washers used for parts subjected to vibration •Are identical washers used in identical parts
Fixing of nuts & bolts
•Are bolts inserted from below, are they visible from outside •Are devices such as limit switches fastened at least by 2 bolts •Are wing nut direction clock wise
Lubrication checkpoints Lubricant storage
•Are lubricant sores always kept clean, tidy, are 5S principles applied •Are lubricant containers always capped •Are lubricant type clearly indicated and is proper stock control practiced
Lubricant inlets
•Are grease nipples, speed reducer lubricant ports and other lubricant inlets always kept clean •Are lubricant inlets dust proofed •Are lubricant inlets labeled with correct type and quantity of lub.
Oil level gauges
•Are oil level gauges always kept clean, are oil levels easy to check •Is the correct oil level clearly marked •Is equipment free of oil leaks, and oil pipes& breathers unobstructed
Auto Lub Devices
•Are Auto lubricating devices operating correctly & supplying correct quantity of lubricants
Lubricatin •Are rotating, sliding parts, and transmission well lubricated g condition •Are the surroundings free of contamination by excess lubricant
Transmission System checkpoints V-Belts & Pulleys
•Are any belt cracked, swollen, worn out, or contaminate by lub. •Are any belts twisted or missing. Are any belts stretched or slack •Are multiple belts under uniform tension and all of the same type •Are top surfaces of belts protruding above the pulley rims? Are the bottoms any pulley groves shiny (indicating a worn belt or pulley) •Are pulleys correctly aligned
Roller
•Are any chains stretched 9indicating worn out pins or bushings
chains
•Are any sprocket teeth worn, missing or damaged •Is lubrication between pins and bushings sufficient •Are sprockets correctly aligned
Shafts, •Is there any overheating, vibration, abnormal noise due to excessive Bearings & play, or lack of greasing. Are any keys or set bolts loose or missing Couplings •Are any couplings misaligned or wobbling, Are any seals worn out Gears
•Are gears rightly lubricated with proper amount of lubricant. •Are any teeth missing, damaged worn out or jammed •Is there any unusual noise or vibration
Hydraulic checkpoints Hydraulic Checkpoints
•Is there correct quantity & level indicated for fluid in the reservoir •Is fluid of correct Temp. And is min & max for temp. indicated •Is fluid cloudy (indicating air entrapment •Are all fluid inlets & strainers clean, are any suction filters blocked •Are any fluid reservoir breather filters blocked •Are fluid pumps operating without any unusual noise or vibration •Are hydraulic pressure correct, and are operating ranges displayed
Heat Exchangers
•Is any fluid or water leaking from fluid coolers or pipes
Hydraulic Equipment
•Are there any fluid leaks ? Are hydraulic properly fastened?
Piping and Wiring
•Are all pipes and hoses fastened tightly?
•Are temp. differences between fluid & water inlets & outlets are correct ? Are any tubes blocked •Are hydraulic devices operating correctly without speed loss or breathing? Are hydraulic pressure correct? And all gauges working •Are there any fluid leaks? Are any hoses cracked or damaged? •Are all valves operating correctly? Is it easy to see whether valves are open or closed/ Are any pipes, valves unnecessary?
Pneumatic checkpoints FRLs
•Are FRLs clean? Is it easy to see inside of them? Are they fitted right way around? •Is there sufficient oil. And are the drains are clear? •Is the oil dip rate correct ?(approx 1 drop for every 10 strokes) •Are the FRLs installed not more than 3 m from the equipment? •Are the pressure adjusted to the correct value and operating ranges are clearly indicated?
Pneumatic Equipment
•Is compressed air leaking from pneumatic cylinders or solenoids? •Are all pneumatic cylinders and solenoid valves firmly fastened? •Are any pistons dirty, worn, damaged? •Are the speed controllers installed right way around? •Is there any abnormal sound or overheating of solenoid valves, and are any lead wires chafed or trailing?
Piping and Wiring
•Are there any places in pneumatic pipes or hoses where fluid is liable to collect? Are all hoses and pipes clipped firmly in place? •Are any hoses cracked, damaged, are there any air leaks? •Are valves operating correctly and open and close position known
Electrical Checkpoints Control Panels
•Are the interiors of distribution boards, switch boards, and control panels kept clean, tidy, and well organized by the application of 5S activities? Have any objects or flammable materials been left inside •Is the wiring inside control panels in good condition? Are any wires coiled or trailing? •Are all ammeters and voltmeters operating correctly? •Are any switches, bulbs broken? Do all switches work correctly? •Are panel doors in good condition? Do they Open & close easily? •Are there any unused holes? Are control panels water& dustproof?
Electrical Equipment
•Are all motors free of overheating, vibration, unusual noise & smell •Are al motor cooling fans and fins are clean? •Are any bolts loose? Are pedestals free of cracks and damages?
Sensors
•Are all manual switches clean and free of damages & excessive play •Are all switches installed in the correct position •Are the interiors of limit switches is clean? Are any wires coiled or trailing? •Are any limit switch dogs worn, deformed, or of the wrong shape?
Electrical Checkpoints – Cont. Sensors
•Are all photoelectric switches and proximity switches clean and free of excessive play? •Are any sensors out of position? Are correct positions clearly indicated? •Are all lead wires un-chafed, and is insulation intact at entry points?
Switches
•Are all switches installed in the correct position •Are all manual switches clean and free of damages & excessive play •Are emergency stop switches installed in appropriate locations and are they in good working condition?
Piping and •Are any pipes, wires, or power leads loose or unsecured? Wiring •Are any ground wires damaged or disconnected? •Are any pipes damaged or corroded? Are there any bare wires or wires with damaged insulation? •Are any wires coiled on the floor or dangling overhead?
CL ASSIFI CATI ON O F ABNO RMAL ITI ES (FUGUA I) (Human-being Type
Classification
I
Non-fulfillment of Basic Conditions
II
Non-observance of Use Conditions
Weakness) Description
Insufficiency of cleaning, oiling and tightening
Although use conditions for facilities and equipment exist and set at the design s tage, such conditions are not observed. Example : Electric current, voltage, number of rotations, temperature, speed etc.
III
Leaving deterioration unattended
IV
Inherent design weaknesses
V
Shortageof Skills
Fail to identify deterioration and to restore correctly, i.e. not conducting correct inspection/ examination or preventive repair to restore ori ginal conditions of equipment
Lack of technical expertise at the stages of design, manufacturing, and work execution, as well as errors
Repairerrorsandoperationalerrors
EXAMPLE OF ABNORMALITY ( LOOSE FITTINGS )
EXAMPLE OF ABNORMALITY ( LEAKAGES )
White tags for operators
Red Tags to be attended by Maint.
Equipment Name ………………
Equipment Name ………………
Control No……………………..
Control No……………………..
Date of detection……………….
Date of detection……………….
Detected by……………………..
Detected by……………………..
Description of Minor defects
Description of Minor defects
………………………………….
………………………………….
…………………………………..
…………………………………..
………………………………….
………………………………….
ABNORMALITY [FUGUAI] IDENTIFICATION SHEET TPM CIRCLE
. o N .l S
n o ti c e t e D f o e t a D
PERIOD:
t n e m p i u q E f o tr a P
n o it a c o L
yt li a m r n o b A
n o it ip r c s e D
s s e n ) ka W / e R ) ( W t G p . g a q . T E (A
EquipmentWeakness A'; Major Flaws B: Unfulfilled Basic conditions C InaccesibleAreas D Contaminationsources E QualityRelatedDefects F Unnecessary & onourgent items G
Unsafe palce
s s e n k a e W n a ) mV u .. H (I
f o t c a p Im
tily l a m r o n b A
f o s e s u a C
yt li a m r o n b A
s e r u s a e m r e t n u o C
) D S M / D S /
y c n e g r U (U
HumanWeakness I : Non-observance of basic conditions II. Non-observance of Use Conditions III.LeavingDeteriorationunattended IV.InherenetDesignWeakness V:ShortageofSkills
yt iil b i s n o p s e R
te a D t e g r a T
e t a D e c n a il p m o C
IMPACT 1. Breakdowns 2. Readjustments 3.Quality 4.Safety& environmen 5.Others
ABNORMALITY [FUGUAI] IDENTIFICATION SHEET TPM CIRCLE :-H5 TPM CIRCLE (Hot Strip M ill)
Sl. No.
Date of Part of Abonrmality Location Detection Equipment Description
1
8/5/01
CJCFILTER Cellar
2
8/5/01
CJCFILTERC ellar
3
8/5/01
ELCfilter
Cellar
4
8/5/01
Cooler
Cellar
5
8/5/01
Illumination Cellar
6
8/5/01
Electrical wiring
Cellar
7
8/5/01
Lighting
Cellar
8
8/5/01
RCpump
9
8/6/01
Cellar
Cellar
Cellar
Tag Red/ White
Filter is not properly fixed Pipingnotok Pipingnotok Temperature gauge mounting not ok Celler light not ok Wiring are not ok Tube light wiring defective Wiring are not ok Illumination is not sufficient
W W
F A
W
*** Urgency TARGET Complian U/SD/ DATE ce Date MSD
*Eqipment ** Human Impact of Causes of Counter Weakness weakness Abnormali Abnormalities Measures (A...G) (I…V) ties I III
A
III
Envoironme Design defect nt Hard to Ignorance access Hard to Design defect access
Base to be modified
SD
20-Aug-01 15-Aug-01
Accesibility
SD
20-Aug-01 20-Sep-01
Piping to modify
SD
20-Aug-01 20-Aug-01
W
A
II
No indication
Loosness
To be tighten
R
F
II
Vissibility
Safety
To provide extra SD light
Ignorance
To be set right
Ignorance
Tobesetright
R
B
II
False indication
W
B
II
5S
W
D
II
Loose Trippage of connection motor
R
G
I
Unsafe condition
* Eq u i p m e n tW e a k n e ss * * H u m a n W e a k n e ss A'; Minor Flaws I : Non-observance of basic c onditions B: Unfulfilled Basic conditions II. Non-observance of Use Conditions C InaccesibleAreas III.LeavingDeteriorationunattended D Contaminationsources IV. Inherenet DesignWeakness E QualityRelatedDefects V:ShortageofSkills F Unnecessary & nonourgent items
Bulb fused
U
SD
U
New wiring to be done Provide sufficient illumunation
IMPACT 1. Breakdowns 2. Readjustments 3.Quality 4. Safety &environment 5.Others
20-Aug-01 20-Aug-01
20-Aug-01 20-Aug-01 20-Aug-01
20-Aug-01 20-Aug-01 SD
20-Aug-01 20-Aug-01
U
10-Aug-01
8-Aug-01
*** URGENCY U- Urgent SD- Shutdown MSD- Major Shutdown
SUMM ARY OF ABNORM ALITIES A Sl. No
Category
I
Non Observance of Basic Conditions
II
Nonobervance of Use Conditions
III
Leaving deteriorations unattended
IV
Internal Design Weaknesses Shortage of Skills
V
TOTAL
Major Flaws
BC
DEF
Unfulfilled Inaccessible Source of Basic areas conditions
G Source Unnecessary Unsafe
contamination Quality & non Defects urgentitems
places
SUMM ARY OF ABNORMALITY TPM CIRCLE: - Compactor Sl.no
Ca te gory A B C D E F G Equipme nt wea kness Minor Fla ws Unfulfil le d Inac cessible Source of Source Unnecessar y Unsafe Basic ar ea s contam ination Qual ity & non pla ces Huma nw e a kne ss conditions De fe cts urge ntite ms
I
Non Observance of Basic Conditions
II
Nonobervance of Use Conditions
III IV V
1
Leaving Deteoriratio n Unattended
64 3
2 4
2
3
Internal Design Wea kness
4
Shortage of Skills
4
1
Total
9
12
2 1
5 2
19 11
1
1
2
9
2
1
1
9
3
1
4
12
4
9
1
5
Total
13
10
61 Format 3.4
Thorough Cleaning (Touch and Clean every Corner)
Lists
List of Defects
List of Hard to Access Areas
List of Sources of contamination
List of Questions
List of Unnecessary & Nonurgent Items
Analyze Abnormalities & Planning Countermeasures • Gathering the data on Abnormalities & Faulty Places • Analyzing the Abnormalities for the root cause and Decide countermeasures • Develop Countermeasures & Kaizen action plan. • Fixed deadlines to be stated on tags. • Follow up plan at least weekly, disseminate information to all members.
Jishu Hozen Step - 1 Activities Performed
Present Status
Jishu Hozen training imparted
Completed
Cleaning Plan prepared
Done
*
Initial Thorough cleaning of machine and identification of fuguais
Completed
*
Classification and summary of fuguais
Under Progress *
* Show the cleaning plan, Fuguai identification sheet & summary matrix in next slides
ABNORMALITY STATUS CATEGORY WISE
SAMPLE
250
200
s e tii l a 150 m r o n b A100 f o . o N 50
0 Minor Flaws
Unfulfilled Basic Condition
Inaccessable Area
Source of Quality Defect Contamination Sources
Type of Abnormalit y
Unecessary Items
Unsafe Places
Identified
Corrected
Jishu Hozen Audit Step 1: Initial Cleaning
Audit
Item
1. Cleaning of Equipment Main Body
2. Cleaning of subequipment [Oil, Pneumatic & hydraulic pressures; Electrical systems]
Self
JHPillar Committe
Section/ Team name Equipment Name
Date
Desired Audit date
Point Accepted Rejected Acceptable level = Sum of(Item 1-5 level point) + Evaluation point (Item
Audit Date TPM Central Auditor Group Description
Leader
Self More than 90 points
Bad 1Point
Poor 2Point
JHPillarCommittee More than 85 points
Passable 3Point
Good 4Point
TPMCentral More than 80
Excellent 5Point
How Well are the dust, oil and grease, and chips removed? How about the condition of work and tools? (Such areas as tools and jigs surfaces, chucks, sliding portion, chute, frame, bed, piping and wiring etc.) Free from loosening, chattering, vibration, exessive wear and heat buildup (in areas as bolts, nuts, jigs, rotation portions, sliding portions and chute etc.)
Free from dust, oil and grease or any other foreign materials(cylinder, solenoid, three point set, motor limit switch, belt, proximity switch, photoelectric tube, inside & outside of control box, instruments, etc.) Free from loosening, chattering, vibration, exessive wear and heat buildup (motors, solenoid valve, limi t s witch inst allation board, relay, wiring, bolts and nuts etc.) Free from dust,dirt and oil s tain (Lubricator, oil cups, measuring instruments, cap of oil filter, oil supply piping, etc.)
3. Lubrication
Proper oil level and oil flow rate, free from loosening, chattering, and vibration. (Check for contaminated oil, oil deterioration, loose piping joints, valve, speed control, oil t emperature etc.)
Cleaning condition of tools, measuring instruments and gauges and spare parts Are the covers, name plate and label in good condition? Are the unnecessary 4. Cleaning parts, products and replacements parts in good order? around the equipment and Are the accepted products properly segregated from rejected products? machine Are the proper passages provided? No flying dust from adjacent equipment? 5. Counter measures for the causes of dirty equipment and improving hard to access areas
Has any lis t s howing the sources of dust, dirt, oil leakage and the areas difficult to keep clean been prepared? And it there any future plan for cleaning? Have the cover and houe keeping utensils been improved? Is there any point you should check while performing the house keeping? Has the responsibility for cleaning the areas been properly assigned to each operator?
6. Employment Has TPM been weel understood and of TPM are all members participating in the Technique activities?
Evaluation point Diagnosis
10 point
20 point
30 point
40 point
50 point
7 Steps of Autonomous Maintenance Autonomous Management Standardization Autonomous Inspection General Inspection Preparing Tentative Cleaning, Lubrication, Inspection & Retightening Stds. Countermeasures against Sources of contamination & Hard to Access areas
Initial thorough Cleaning
Preparation
Purpose of Step-2 • Eliminate sources of contamination that generate dirt & stains
• To improve places which are difficult to access for cleaning, lubrication, inspection, tightening
• Enable Learning in doing JH Kaizens • Improve Visuals on the equipment
Devising countermeasures to Eliminate Sources of Contamination
Hard to Access Areas • Time consuming Places • Places difficult to work
Eliminate the Source Contain (localize) the Contaminant Shield (Protect) the Affected part Improve Cleaning Method
Eliminate Need to Access Reduce need to (Frequency)
Improved Method of C, L, I & R
approach
Less Time & Effort
Improve Accessibility
ELIMINATING SOURCES OF CONTAMINATION •
ELIMINATE THE POINT GENERATING THE CONTAMINATION.
I •
•
IF THE ABOVE IS NOT POSSIBLE, CONTAIN THE CONTAMINATION BY DOING KAIZENS. IF BOTH THE ABOVE ARE NOT POSSIBLE, DEVELOP A CLEANING STANDARD TO RETAIN THE CONTAMINATION WITHIN THE PERMISSIBLE LIMIT.
Jishu Hozen : Step-II
LIST OF SOURCES OF CONTAMINATI ON o N .l S
f o e t a D
n o it a v r e s b O
t n e m p i u q E f o tr a P
f o e cr u o S
n io t a n i m a t n o C
f o e p y T
n io t a n i m a t n o C
f o st n e t n o C
s e r u s a e m r te n u o C
r o t u c e x E
te a D d e n n a l P
SOURCES OF CONTAMINATION
TYPE OF CONTAMINATION
Product
Leaks, spills, Spurts, Scatters, Overflow Spillage, Scattered on ground
Lubricants Gases
Scrap
Leaking, Silt, seeping oils Leaking Compressed Air / Gases etc. Leaks, Spurts, Scatters, Overflow Flashes, Cuttings, Papers etc.
Other
People, Forklift Trucks etc.
Liquids
n o it e l p m o C f o te a D
LIST OF SOURCES OF CONTAMINATION Department:-HotStripMill
Sl.No.
TPMCIRCLE:__________________
Date of Part of Source of @Type of Responsi Planned Date of Countermeasures Observation Equipment Contamination Contamination bility Date Complition
1
4/10/01
Surrounding
Gla nd le a ka ge .
Se e ping oil.
2
4/10/01
Pump tra y.
Filte r cha nging.
Spilla ge o il.
3
20/09/01
Ace Sta nd.
Le a king joints
Le a king oil.
4
20/09/01
Le ve l/Pr. Gauge.
Atmosphe re dust
Dust
Gla nd se a l t o be repaired every 2 year To be c le a ne d just after job is over Pipe jointsto be checked once a year To be cle a ne d on every shutdown.
@ TYPE OF CONTAMINATION Leaks,Spills,Spurts,Scatters,Overflow, dust Spillage,Scattered on ground Leaking,Silt,Seeping oils Leaking Compressed Air/Gases etc. Leaks,Spurts,Scatters,Oveflow Flashes,Cutting,Papers etc. By people,Forklift,Truck etc.
TPM CIRCLE S.K.Ojha
20/02/2002
20/02/2002
28/01/2002
4/2/02
S.K.Ojha
15/02/2002
15/02/2002
R.K.Purbe. 15/02/2002
15/02/2002
EXAMPLES OF LOCALISED CONTAINMENT
Before
After
Usage of localized guards
Countermeasures against source of contamination Oil Localisation Before
After
Localised guards The return oil flow from the feed drive gears splash and spread all around the open space inside the machine there by getting contaminated. To avoid the contamination, the return oil flow is channalised from the feed drive gears directly to the lubrication tank
HARD-TO ACCESS-AREAS WHILE DOING STEP – 1, MANY AREAS MAY BE FOUND, WHICH ARE DIFFICULT FOR CLEANING, INSPECTION AND LUBRICATION. ACCESSIBILITY OF THESE AREAS NEED TO BE IMPROVED THROUGH SUITABLE KAIZENS.
- PROVIDE INSPECTION POINTS FOR EASE OF INSPECTION. - PROVIDE PROPER INSPECTION WINDOWS FOR THE PARTS LIKE V-BELTS - PROVIDE SPACE/REACH TO CLEAN PARTS - PROVIDE TOOLS/TACKLES TO LUBRICATE
LIST OF HARD TO ACCESS AREAS Department : _ _______________
. o N .l S
n o ti a rv e s b O f o e t a D
,I L , C s e ri o g e t a C
* Difficult state: X-Lessdifficult Y-Moderatedifficult Z- Very Difficult
TPM Circle : _ ________________________
* te ta S lt u c i ffi D
n o tir o P tl u ic ffi D
** Tag R-Red, W-White
f o s t n e t n o C
s re u s a e m r e t n u o C
** n io t a c if i s s la C g a T
y itl i b i s n o p s e R
te a D d e n n a l P
n io t le p m o C f o te a D
LIST OF HARD TO ACCESS AREAS Depar tment: -HotStripM ills
S l N o.
1
2
3
Date of Categories Observati Cleaning (C), on Lubrication (L), Inspection (I) 4/11/01
25/12/01
5/1/02
I
C
C
T PM CIRCLE:D ownColier #1
Difficult Portion
AccS. tand. (Height)
Aprochto tank top due to loose hose pipe Cleaning not possible of ELC & CJC Base
* Difficult state: X-Lessdifficult Y-Moderate difficult Z- Very Difficult
Difficult State*
Z
Countermeasures
One Permanent Steel Plateform to be made for aproach during N2 checking & F illing. All hose pipe to be modify to steel pipe
**T ag Responsi Planned Classificat bility Date ion (R/ W)
Date of Complition
w
V.K.Sinha 15/02/02
20/02/02
W
S.K.OJha SD2002
1/5/02
W
R.K.Purbe 28/02/02
28/02/02
X
New base to be made of CJC & E LC filter unit Z
** Tag R-Red, W-White
DIFFICULT TO LUBRICATE - EASY TO LUBRICATE
Before Difficult to Lubricate the oil to gear box
After Easy to Lubricate the oil to gear box
DIFFICULT TO INSPECT- EASY TO INSPECT Before
Difficult to Inspect the belt condition
After
Easy to Inspect the belt condition
Why - Why Ana lysi s Breakdown / Physic al Phenomenon:
Q u e s tio n
An s w e r
What is your Final Action, so that it is OK
WHY
ANS WE R
AC T IO N
Why Did you take above action
Due to
Action neede d
Why 1 Why 2 Why 3 Why 4 Why 5
Root Caus e (1) (2) (3) (4) (5)
JH
PM
D e s ig n
Poor Basic Condition Poo r Operating Condition Deterioration Weak Design Poor Skill
NOTE: This F orm is to be filled immediately after the machine is started
E&T
Breakdow n / Physical Pheno menon: Cylinder doesn't Operat e Smoothly
Q u e s tio n
An s w e r
What is your Final Action, so that it is OK Cleaning Strainer After Cleaning Strainer is it OK Yes
WHY
ANSWER
ACTION
Why Did you take above action
Due to
Action needed
Why 1
Why did you clean the strainer
Strainer was clogged
Why 2
Why strainer was clogged
Oilwasdirty
Why 3
Why oil was dirty
Dirt enter in the tank
Why 4
Why does dirt get in
Why 5
Why was hole made
Root Cause (1) (2) (3) (4) (5)
Clean strainer DrainoilandClean Prevent scatering of chips and cutting fluid
Upper plate of tank has hole Plug hole and gap and gap Repair error during Standardize repairs maintenance work
JH
PM
Poor Basic Condition Poor Operating Condition Deterioration Weak Design Poor Skill
NOTE: This Form is to be filled immedi ately after the machine is started
D e s ig n
E&T
KAIZEN IMPLEMENTATION SHEET T H EM:E -
I D EA :-
B EFO R :-E
AFT E:-R
T PM CI RCL:E -
K AI Z E N No.:
DATE:
A N AL Y S I S :-
RE S U L T :-
B ENE FI:-T
H O RI Z O N T AL P LAN :-
Machine Plan Comp.
KAIZEN IMPLEMENTATION SHEET THEME:REDUCE
IDEA:TO UPGRADE FILTERS AND INSTALL OIL
EQUIPMENT FAILURE BY IMPROVING OIL CLEANLINESS
CLEANING M/C
BEFORE:
AFETR: ELC M/C INSTALLED AND UPGRADED THE BENEFIT:
PROPER FILTERATION SYSTEMS WERE NOT AVAILABLE TO MAINTAIN OIL CLEANLINESS LEVEL OF NAS VALUE 6
TPM CIRCLE:
KAIZEN NO: 1
CASTER #1 HYD ROOM
DATE:10.03.02
FILTERS MODIFIED 5 MICRON ELC M/C FOR TANK FILTERS OIL CLEANING
CYLINDER SEAL CONSUMPTION 25 20 15 S O N 10 5 0
NO OF DRIVE CYL SEAL CONSUMED
01- 02
ANALYSIS: WHY SEAL FAILS? PRESENCE OF FINE DIRTS IN OIL WHY DIRTS IN OIL ? POOR OIL CLEANLINESS WHY POOR OIL CLEANLINESS? ABSENCE OF PROPER OIL
CLEANING SYSTEM
HORIZONTAL PLAN:
RESULTS: 12 NAS LEVEL OF CASTER OIL 10 E U L A V S A N
02-03
MACHINE: CAN BE IMPLEMENTED IN CASTER#2 &3
8 6
PLAN:TO BE IMPLEMENTED BY OCT 2002
4 2
COMPLIANCE: IMPLEMENTED IN
0 N JA
B FE
CH AR
L RI AP
AY M
NE JU
LY JU
G AU
M
ACTUAL
IDEAL
P SE
O
CT
NO
V
C DE
BOTH CASTERS
T HE M E :
KAIZEN
L OS S NO
MACHINE:
LOSS STRUCTURE: To reduce Cleaning time BENCH MARK
30 Sec
TARGET
5 Sec
8A
Cleaning Time Reduction
COUNTERMEASURE: Before Oi lC
Cleaning the contaminated material deposited in the magnet
hu te
Contaminated material
Magnet
takes more time
A N A L Y S IS : WHY 1 Cleaning the magnet takes more time
WHY 2
WHY 3
Iron particles not coming out easily from magnet
Due to magnetic property
R E S UL T : Before
Sec 30
Oi lC
hu t
16.03.2001
Contaminated material e
Polythene Magnet
•
Time saving / month
•
Timings saving / Year
= 533 min = 6396 min
Effortless activity
Oil tank No cleaning remove Polythene paper and fix new polythene paper
HORIZONTAL DEPLOYMENT : After Area
30 Sec
BETTER 15 5 Sec 0
KAIZEN FINISH
BENEFITS :
•
Remove magnet & cleaning by brush with diesel then fix magnet
15.03.2001
After
Paper
Oil tank
KAIZEN START
S.Ravindharan V.Mohan P.Comarasen K.Patchaiappan
IDEA: To provide a polythene paper on t he magnet to collect contaminated material
PROBLEM:
13B5SL
TEAM:
Status
Socket
13
Hex
15
Special
13
T HEME:
KAIZEN
LOSS N O.
To Reduce Cleaning Time inside the machine area in rolling machine
BENCH MARK
3 min / shift
TARGET
“Zero”
8A
MACHINE:
LOSS STRUCTURE: Cleaning Time Reduction
CGR17H
TEAM: J. Srinivasan
KAIZEN START
S.Jayaraman IDEA: To provide gaurds in the product discharge chute & providing conveyor
PROBLEM:
COUNTERMEASURE:
G. Devanathan BENEFITS :
After
Before
03-06-2001
Krishnamoorthy KAIZEN FINISH 21-06-2001 D.Sivakumar
Gaurd Time saving = 3 Min / Shift Man hours saved per year = 15 hours
Time taken for cleaning inside the machine area is more
Other Benefits No Spill Over of Products Tray
Product spillover A NA LY SIS : WHY 1
Cleaning time is more in
Problem : Cleaning time is more WHY 2
WHY 3
Products get
Basic design
spilled over
inside the
inside the
machine area
machine area
in rolling
and oil le akage
machine
from chute
No oil leakage
Oil
S-Conveyor Oil Pit
R ESUL T :
HO RI Z ON T AD L EPLO YMEN:T
mts 3 min / shift 3
Better
of chute
No of rolling machines Identified
: 9 Nos.
Implemented : 6 Nos. Zero 0
Before
After
Target Date
25-09-2001
THEME:
KAIZEN
LOSS N O.
To reduce Inspection time
BENCH MARK
30 sec / Day
TARGET
2 sec / Day
MACHINE:
LOSS STRUCTURE: 8A
Inspection Time Reduction
COUNTERMEASURE: Before
KAIZEN START 10.05.2001
Karunairaja
IDEA: To bring the pressure gauge for K.O. system outside the machine for easy inspection
PROBLEM:
10B3S
TEAM: J. Sriram
After
Franklin
KAIZEN FINISH 25.05.2001
Sivakumar Ramalingam
BENEFITS : Time saving = 28 sec / Day Man hours saved per year = 15 hours
Inspection is very difficult and taking more time in the pressure gauge for K.O. system
Pressure gauge Inside the M/c
Difficult to Inspect A NA LY SIS : WHY 1
Inspection is very difficult and it is taking
Problem : Inspection is difficult WHY 2
WHY 3
Pressure gauge
By machine
kept inside the
Other Benefits
Pressure
Inspection becomes easy
gauge Outside the M/c Easy to Inspect
R ESULT:
HORIZONTAD L EPLOYMEN:T
Sec. 30 sec / change 30
Better
design
No of Areas
machine
Identified
15
: 5 Nos.
moretime in pressure gauge for K.O. system
2 sec / Day 0
Before
After
Implemented : 5 Nos.
IMPROVEMENT IN VISUALS ON THE EQUIPMENT Points / Ideas to create Visual Workplace (To Create Orderly Shop Floor)
Level Indicators, Meters, Gauges, Dials 1.
Oil level indicator for levels
2. Red, Orange and Green zones on gauges, meters for ‘Go’, ‘Take Corrective Action’ and ‘No Go’ Situations 3.
Gauges on all pressure line – close to the point of use
4.
Transparent covers for panels, belts to show direction
Covers, Drives, Doors 1. Acrylic sheets to expose closed drives 2. Transparent doors wherever possible 3. Install Inspection holes on safety covers. 4. Provide inspection windows for critical moving parts. 5. Where sight glasses are used, make sure that they are clean and High / Low points are boldly marked and colour coded, so as to see at a glance. 6. Identify Covers, which are removable by colours coding them.
Possible points of Application
Jishu Hozen Audit Step 2: Countermeasures for the causes of forced deterioration and improving Hard-to-Access Area Audit
TPM Circle
Date
Desired Audit date
Point Accepted Points = Sum of Item 1-6 points
Audit Date
TPMCircle
JH Team TPM Centarl Auditor Group
Item 1. First Step Maintenance St ate
Section/ Team name Equipment Name
Description
and tidiness?)
3. Countermeasures for sub-equipment
Are the causes trouble such as dirt, dust, oil leakage, air leakage summarized into a list, and are countermeasures for the causes taken? Are the hard to clean areas summarized into a list, and are the state of contrivance and KAIZEN good? (Are cleaning tool covers removed, put in order and neat?)
Are the cause sources such as dirt, dust, oil leakage, air leakage summarized into a list, and are 4. Cleaning around countermeasures for the causes taken? the equipment and machine Are the hard to clean areas summarized into a list, and are the state of contrivance and KAIZEN good? (Are cleaning tool covers removed, put in order and neat?) 5. KAIZEN and maintain
Are the oil labels attached in accordance with the lubrication control st andards so that any body can perform lubrication? Is every body participating in the activity?
6. Activity State
Bad
Are they taking advantage of the independency in the kaizen activity?
2Point
Leader
Rejected
JHTeam
More than 90 points
Is cleaning level of first step (Initial Clean up) good, and is it maintained?
Are the cause sources such as dirt, dust, oil leakage, air leakagesummarized into a list, and are 2. countermeasuresfor the causes taken? Countermeasures for equipment main Are the hard to clean areas summarized into a list, and are the state of contrivance and KAIZEN good? body (Are cleaning tool covers removed, put in orderliness
SectionChief
Poor 4Point
TPMCentralGroup
More than 85 points
Passable 6Point
Good 8Point
More than 80 points
Excellent 10Point
Remarks
7 Steps of Autonomous Maintenance Autonomous Management Standardization Autonomous Inspection General Inspection Preparing Tentative Cleaning, Lubrication, Inspection & Retightening Stds. Countermeasures against Sources of contamination & Hard to Access areas
Initial thorough Cleaning
Preparation
Continuous Maintenance and Management of Basic Equipment Conditions
• Prepare Standards for Cleaning, Lubrication, Inspection & Re-tightening Places & Location
Schedule/Frequency
Method
Tools & Jigs to be used
Standard/Level
Target Time
• Enhancing Equipment Reliability & Maintainability • Preparing standards that can be followed easily • Use of Visual Control • Kaizens for reduction in time
C, L, I, R Standards Implementing Cleaning, Lubrication, Inspection, & Retightening Standards Gap with target time Kaizen Feedback
(Implement & Confirm)
Audit Passed
VISUAL CONTROLS Activity
CLEAN LUB
INSPECTION
Symbol
Tools
I S NOC
DAILY INSPECTION ROUTE
BEFORE STEP-3
9
8
7
1
6
2
5 3
4
Machine - Shigiya 138 - Grinding Machine
5.5-4.1 A
TPM J.H : KEY POINTS OF ACTIVITY (PROCESS) EXAMPLE OF TENTATIVE STANDARD JISHU-HOZEN TENTATIVE STANDARDS
Group: Comp Leader: Sudip.Das Tag :ME/ Comp/ 2 0 2
(Ins ect ion,Cleanin ,Lubrica tion,Ti htenin ) Location:Comp re s sor House Equipment:Compress or-1 master!A1
Part DESCRIPTION
ST AND AR D
I-1
OIL LEVEL IN TANK
Between low & high level mark of sight glass.
I-2
LOADING & UNLOADING SYSTEM
I-3
METHOD
TOOL
N
--
110A= loading 65A=Unloading
N
--
TANK OIL
No sediments
IN
--
I-4
BLOW-DOWN VALVE
NO JAMMING
IN
I-5
OIL STOP VALVE
NO J AMMING
IN
C-1
AFTER COOLER
C-3
SUCTION STRAINER AIR FILTER
C-4
M/C OVER ALL
C-2
C-5 C-6 C-7 C-8 C-9 C-10
MOISTURE TRAPPER MAIN OIL FILTER BEARING OIL FILTER LOADING SOLENOID UN-LOADING SOLENOID ACTUATOR
OIL COOLER INSIDE CONTROL PANEL C-12 INSIDE FERULE JOINTS IN T-1 PIPE TYRE COUPLING T-2 BOLTS C-11
FILL TO MARK Inform P.M R ep lac e
WIPE
NO DIRT
WIPE
R ep lac e
NO DIRT
WIPE
Comp air
NO DIRT
WIPE
Comp air
NO DIRT
WIPE
Comp air
WIPE
NO DUST
WIPE
NO DUST NO DUST OR OIL SPILLS
WIPE
NO DUST
WIPE
NO DIRT
NO DIRT NO DIRT OR OIL SPILLS
WIPE
WIPE WIPE
Re vi se d : 4 ti me s
ACT ION If Time Abnorma l (min)
Inform P.M Inform -P.M Inform P.M Inform P.M Comp air R e pla c e Inform P.M Inform Comp air P.M Comp air R ep lac e
NO DUST OR OIL SPILLS
Prepared : 1.10.2001
Comp air CRC,CTC
Inform P.M Inform P.M Inform P.M Inform P.M Inform P.M
Alt
RESP W M
2
O
HH,NM
5
O
SD,AD
O
10
--
INTERVAL
DY
HH,AR
5
O
AK, NMu
10
O
AK,JLG
10
O
5
O
SD,AK
O
DP,JLG
5 15
O
5
O
15 15
JLG, KM
NMu, AR BPB,AR
O
HH,NM
O
BPB,AR
15
O
15
O
SD,DP
15
O
AK,JLG
120
O
JLG, KM
120
O
AD,KB
SD,AD
NO LEAKS
N
R ep lac e
10
O
DP,AK
NO SLACKNESS
IN
Inform P.M
15
O
SD,AK
5.5-4.1 B master!A1
TPM J.H : KEY POINTS OF ACTIVITY (PROCESS) EXAMPLE OF TENTATIVE STANDARD JISHU-HOZEN TENTATIV E S TA NDARD (C LEANING, CHECKING GROUP & - JH
Prepared 12/1
EQUIPMENT:- SLA G GRANN ULATION, SHE LL & T UYERE PUMP LEADER -D.BANDYO Revised : nil Loca tio n:- PUMP -HOUSE PART PUMP 1.1 PUMP BASE 1.2 BRG. HOUSING
STANDARD
METHODTOOL
NO VIBR AT ION & NOISE NO OVERHEA TING(>80 DEG C), NO AB NORM AL SOUND NO OVERHEA TING(>80 DEG C), NOISE
2.2 MOTOR NO DIRT OR OIL SPILLS BODY
W
RESP
M
I
5
O
KNR,
I
INFORM TO P/M
2
O
SRC, KNR, SA
INFORM TO P/M
3
O
GCP, SC, RC
INFORM TO P/M
5
O
DB, GCP
10
O
GCP, GN, KNR
I
@ WIPE
5
O
ARD, SB,SA
INFORM TO
TERMINAL & PANEL BOX
NO LOOSENESS
3. COUPLING
NO OVERHEA TING(>80 DEG C), NOISE
I
NO OVERHEATING
I
6, VALVES
INTERVAL
INFORM TO P/M INFORM TO P/M
2.3
5. BELTS
TIME (MIN)
D
1.3 CASING . NO VIBR AT ION & BASE NOISE
4.PULLEY
ACTION IF ABNORMAL
P/M
@ INFORM TO P/M
NO ODOUR NO LEAKAGE
I
@
10
INFORM TO P/M INFORM TO P/M
2
P/M
5
O
5
0 0
SB,ARD,SA SB,ARD,SA SB,ARD,SA
0
DB,ARD,SB
LUBRICATI ON LUBE POINT
STANDARD
2.5 M OTOR BR G. DE
70% FULL WITH LUBR ICANT
2.6 MOTOR BRG. NDE
70% FULL WITH LUBR ICANT
1.5 PUMP BR
70% FULL WITH LUBR ICANT
1.4 PUMP BR
70% FULL WITH LUBR ICANT
70% FULL WITH LUBR ICANT 70% FULL WITH 1.6 BRG. HOU LUBR ICANT 1.6 GLAN D
LUBE TYPE & QTY
METHOD TOOL AP-2 & 20 gms manual AP-2 & 20 gms manual AP-2 & 20 gmsm anual AP-2 & 20 gmsm anual AP-2 & 20 gmsm anual HOULIC 6
manual
TIME
INTERVAL
5
O
5
O
RESP GCP, KNR, SC GCP, KNR, SC
5
O
A RD,SB ,TB
5
O
A RD,SB ,TB
5
O
A RD,SB ,TB
O
SRC,SA DB ,
5
TENTATIVE CLEAN LUB INSPECT STANDARDS Jishu - Hozen ( Tentative Cleaning, Lubrication and Inspection ) Standards
Cell : Nozzle Cell EquipmentdescriptionMicromatic : ODGrindingMachine
Illustration
Classification
Equipment number : M12045
No.
Placeorsection
Standards
CirlcenameNOZH : 1
Method
Person
Tools and Time Cycle handling
in
sec (month)
During
During
operation stoppage
charge
Inspection
1
Tailstock
Withintheindicated
Visual
2
Cleaning
2
Tailstock
Freefrommist&dust
Wastecloth
Inspection
3
TableLubrication
Withintheindicated
Visual
LoaderPistion
NoDamage
: Daily;
30
W
Removethe
: Weekly;
3mm
b
OP
W
OP
1200 1M
OP
N
Pistionbl ock
:
I 2
value range 4
b
OP
N
value range
Inspection
W
b
b
Allenkey
: Setting change;
: Maintenance staff;
: Operator.
Aiders : Visual controls
Indication marks for nuts & bolts
Indication for valve controls
Fan to indicate the function of Chiller Unit
Arrow sign for indicating the rotating direction of Motor
Initial Clean-up ( Cleaning is Inspection) ( Cleaning with meaning) (Doing with purpose) Taking countermeasure for forced deterioration and improving hard to access area
Preparing tentative standards for cleaning and lubrication
Jis hu Hozen Au dit Step 3: Preparation of TPM Circle
I te m
1. Step 1 & 2 maintenace condition I te m
Date
Equipment Name
Point
Accepted
Leader
Equipment Name Desired Audit date
tentative "Jishu Hozen" Standard Audit
Section/ Team
Rejected
Team Name: Audit Date
JH Team
TPM Central Group
Auditor
De scr i p ti o n
Audit Date:
TPM Circle
JH Team
TPM Central Group
More than 90 points
More than 85 points
More than 80 points
Bad
Poor
Passable
Good
Excellent
3 P oin t
6 P oin t
9 P oi n t
12 P o i n t
15 P oi n t
Remarks
Are the 1st Step's (Initial Cleaning) conditi ons and 2nd Step's improvement level maintained? Description
(Cleaning St andard) Is the standard made out according to the equipment and location? Are Cleaning sect ion, locat ion and assi gnment specified? 2. Action standard Are methods and t ools s pecified? Are cleaning t ime and cy cle properly s pecified and for the basic observed? equipment maintenance Are contents clear and understandable by everybody? (Cleaning, (Lubrication St andard) Lubrication, Are kind of lubricati on, amount, c ycl e, method and retightening) assignment specified? requirements Are proper labels applied to lubric ation points? Is the oil ready for lubrication all the time? Is the storage location tidy? (Retightening) Are bolts and nuts loos e? Are there any nuts and bolts t hat have fallen out? I te m Description Are the item s to be observed determined autonomously. 3. Awareness of one's own role in Is the maintenance observed in accordance to the making the standard. standard Are the improvement and new ideas for easy inspection and visual inspection implemented actively?
p1o i n t
p2o i n t
p3o i n t
p4o i n t
p5o i n t
Re m a rk s
p2o i n t
p4o i n t
p6o i n t
p8o i n t
1p0o i n t
Re m a rk s
7 Steps of Autonomous Maintenance Autonomous Management Standardization Autonomous Inspection General Inspection Preparing Tentative Cleaning, Lubrication, Inspection & Retightening Stds. Countermeasures against Sources of contamination & Hard to Access areas
Initial thorough Cleaning
Preparation
Purpose of Step-4 • Bringing up equipment consciousness in the process of measuring & restoring deterioration.
• To understand structures, functions & principles of equipment & learn their optimal conditions to thoroughly check principal mechanisms & parts of the equipment
Preparation for Education & Training Identifying general Inspection Items Basic Items: Machine Elements
Lubrication system
Bolts & Nuts
Hydraulic System
Pneumatic System
Driving Systems
Electrical systems
Equipment Safety
Process Conditions
Additional Items: Specific to the Equipment
Preparation of text for General Inspection Education & Training Schedule Planning for General Inspection Education & Training
Step 5: Autonomous Inspection
Autonomous Inspection is the actual transfer of responsibility for equipment inspection.
Step 6 : Process Discipline • Process discipline is defined as the establishment or improvement of methods and procedures that enable efficiency and repeatability. The objectives include: – Reducing set-up times. – Decreasing manufacturing cycle time. – Reduce Work in Progress. – Institute Visual Control and Inspection Method.
Step7 : Independent Autonomous Maintenance • Independent Autonomous Maintenance is the point at which the AM process becomes self-sustaining.
