03 shrirampistons&ringsltd

8/22/2019 03 ShriramPistons&RingsLtd

1/27

5th TPM National Conference

Session B : Jishu Hozen

(Autonomous Maintenance)

Topic :JH Step 1-4

Presentation by

Mr J P Garyali

Sr General Manager

Shriram Pistons & Rings Ltd


2/27

5th TPM National Conference Page 3.1

Shriram Pistons & Rings Ltd JH Step 1-4

PRESENTATION ON

AUTONOMOUS MAINTENANCE (JISHU HOZEN)

STEP 1 TO STEP - 4

SHRIRAM PISTONS & RINGS LTD.

GHAZIABAD

TPM CLUB ANNUAL CONFERENCE NEW DELHI SLIDE NO. 1

BY : J.P.GARYALI

DATE : 1ST MARCH 2005

OUTLINE OF THE COMPANY


SLIDE NO. 2OUTLINE OF THE COMPANY


3/27



1. OUTLINE OF THE COMPANY

INCORPORATED IN 1972

TURNOVER IN LAST F.Y.

Rs.310 Crores

TURNOVER IN F.Y. 2005 (PLAN)

Rs.350 Crores

OUTLINE OF THE COMPANY

MAIN COMPANY DETAILS

TOTAL AREA

105,000 SQ.M(26 Acres)

ELECTRIC POWER

GOVT. 7000 KVAOWN: 12000 KVA

STAFF

284

230

2476

OFFICERS

WORKMEN

TOTAL EMPLOYEES 2990

TOTAL NO.OF MACHINE

830



4/27



PISTONS RINGS

P I N S ENGINE VALVES

PRODUCTS


HFHF

HONDA FOUNDRY- JAPAN

(Collaboration since 1989)

RIKENRIKEN

RIKEN CORPORATION- JAPAN


FUJI- OOZX- JAPAN


(Collaboration since 1972)KOLBENSHMIDT- GERMANY

FOR PISTONS

FOR RINGS FOR ENGINE VALVES

FOREIGN COLLABORATIONS

FOR PISTONS



5/27



JOURNEY TOWARDS EXCELLENCE

ISO 9001

YEAR 1994

QS 9000

YEAR 1999

ISO 14001YEAR 2001

OHSAS 18001

YEAR 2003

TS 16949

YEAR 2003

TPM EXCELLENCE AWARD

YEAR 2004

CHALLENGE TPM SPECIAL AWARD - 2007


TPM IMPLEMENTATION


SLIDE NO. 8TPM IMPLEMENTATION


6/27



JANUARY 2000

12. DATE OF TPM INAUGURATION

TPM was introduced at SPRL

in


3. T P M POLICY

ZERO FAILURE, ZERO DEFECT & ZERO ACCIDENT

THROUGH INTRODUCTION OF T P M, WITH

PARTICIPATION OF ALL EMPLOYEES.

MAXIMUM PROFITS THROUGH IMPROVEMENT OF

OVERALL EQUIPMENT EFFICIENCY, REDUCTION IN

COST AND INCREASE IN CUSTOMER SATISFACTION



7/27



2. TPM PROMOTION ORGANIZATION

TPM

Secretariat

HOD

Officer

S S

W W W W

Officer

S S

W W W W

HOD

Officer

S S

W W W W

Officer

S S

W W W W

HOD

Officer

S S

W W W W

Officer

S S

W W W W

HOD

Officer

S S

W W W W

Officer

S S

W W W W

Officer

S

W W

HOD

Officer

S S

W W W W

Officer

S S

W W W W

HOD

Officer

S S

W W W W

Officer

S S

W W W W

HOD

Officer

S S

W W W W

Officer

S S

W W W W

HOD

Officer

S S

W W W W

Officer

S S

W W W W

HOD

Officer

S S

W W W W

Officer

S S

W W W

Plant TPM Promotion

Committee (10 Nos.)

Area TPM Promotion

Committee (66 Nos.)

Circles (242 Nos.)

TPM

Secretariat

Executive Director

TPM Steering Committee

H O D H O D H O D H O D H

H O D H O D H O D H O D

MANUFACTURING PLANTS & DEPTTS.

5. Initial Control

6. Education & Training

7. Office TPM

8. Safety, Health & Envimt

3. Planned Maintenance

4. Quality Maintenance

2. Autonomous Maintenance

1. Kobetsu Kaizen

SUBCOMMITTEES


5. T P M IMPLEMENTATION PROCESS

TPM TRAININGS

TPM KICK- OFF

MODEL MACHINE

ACTIVITY

SEMINARS

SMALL GROUP

ACTIVITIES

CONSULTANT AUDIT /GUIDANCE



8/27



IMPLEMENTATION OF AUTONOMOUS MAINTENANCE

STEP 1 TO STEP - 4


SLIDE NO. 13JISHU HOZEN ACTIVITY


PHILOSOPHY BEHIND AUTONOMOUS MAINTENANCE

A workman who is operating a machine or equipment, day in &

day out, is expected to have the best knowledge about the

machine, operation.

If a, little knowledge & training is given to this operator on simple

maintenance areas, it is possible for him to broaden his expertise

towards the maintenance of this machine as well.

(Contd.)


9/27




With each operator, becoming partly a maintenance man also ,

for his machine, results in, huge benefits as given below :

! Enormous reductions in machine breakdowns &

stoppages, through regular inspection & early defect

warnings.

! Drastic improvement in the life of the machines,

components through controlling the forced deterioration

areas, an each machine.

! Prevention of leakage of oils/coolants/Air etc..

!Marked improvement in the availability of the machine

for production.


PREPARATION (STEP 0)

This is the most important step in the successful implementation of the

Autonomous maintenance in on organization.

This comprises of following sub activities.:

1. Making of a plan :

! This includes formation of circles, company wide and allocating

the various machines to each circle. (to create the ownership

concept.)

! Making of inspection formats for Auditing at the end of each Step

activities.

! Making a schedule of the activities to be undertaken under each

step.(Contd.)


10/27




3. Training on the skills of :

! Cleaning : Method, correct tools for cleaning (specific to a

machine)

! Lubrication : Purpose, Type, Method quantity, Period etc.

! Retightening : Purpose, correct fastening methods, use of correct tools

etc.

2. Imparting Trainings

! Regarding the basic working of the machine and the accessories/ Sub

assemblies.

!Training on safety (Both electrical & Mechanical)

! Understanding the conditions of forced deterioration & losses.


CHECKPOINTS FOR NUTS AND BOLTS

Are bolts inserted from below. and are nut visible from the outside ?

Are devices such as limit switches secured by at least to bolts ?

Are wing nuts on the right way around ?

Attachment of

Nuts & Bolts

Are Flat washers used on long holes ?

Are tapered washers used on angle bars and channel ?

Are spring washers used where parts are subject to vibration ?

Are identical washers used on identical parts ?

Washers

Do all Bolts protrude from nuts by 2 3 thread lengths ?Bolts Lengths

Are any nuts or Bolts loose ?

Are any nuts or Bolts missing ?Slight Defects

Check points are developed to help the operator

recognize the abnormalities


11/27




! Check Points for Lubrication

! Check Points for Transmission System

! Check Points for Hydraulic

! Check Points for Pneumatics

! Check Points for Electrical

! Check Points for General Purpose Equipment

SIMILARLY CHECK POINTS ARE DEVELOPEDFOR OTHER PARAMETERS

FOR EXAMPLE :

BASIC APPROACH

Initial Cleaning1

Contamination Sources2

Tentative Standards3

General Inspection4

Autonomous Inspection5

Standardization6

Autonomous Management.7

Through Participationof all Employees.

Implementationof each step.



12/27



CHARACTERISTICS

Activity board for promotion ofJ.H. Activity.

Significant learning FromManager Model M/cs.

Participation of all employees.(Improved 5S)

Designated place for tooling & WIP.


JISHU HOZEN ACTIVITY - MASTER PLAN

IMPLEMENTATION ESTABLISHMENT

OCT- 99 APR- 00 OCT- 00 APR- 01 OCT- 01 APR- 0 2 OCT- 02 APR- 03 OCT- 03

MAR- 00 SEP- 0 0 MAR- 01 SEP- 01 MAR- 02 SEP- 02 MAR- 03 SEP- 03 MAR- 04

1ST LEVEL

MACHINES

(53 MACHINES)

2ND LEVEL

MACHINES

(768 MACHINES)

PERIOD

JAN-04~MAR-06

INTRODUCTION

PERIOD

JUNE-01~MAR-03

PERIOD

APR-03~DEC-03

YEAR

ITEM

PREPARATION

(9 MACHINES)

ACTIVITY

PLAN OF

MODEL MACHINE

PERIOD

OCT-99 ~MAY-01APR- 04

MAR- 05

APR- 05

MAR- 06

STEP-1

STEP 0 STEP 1 - 3 STEP 4 STEP 5 - 6

PLAN COMPLETED

KICKOFF-JAN

2000

CHALLANGETPM

EXCELLANCE

AWARD

STEP-2

STEP-3

STEP-1

STEP-2

STEP-3

STEP-1

STEP-2

STEP-3

STEP - 4

STEP - 4

STEP - 4



13/27



To reduce cleaning / inspection / lubrication time.

To reduce minor stoppages during machines operation.

GOOD

64

21

0

25

50

75

100

Minor stoppages(Th.Nos./Month)

GOALS

OBJECTIVES

To develop operators ability to MAINTAIN and OPERATE,

their own equipment / machines, EFFECTIVELY.

Th.n

os

/MONTH

200

622

60

183

7224

0

150

300

450

600

750

900

1 2

CLEANING

INSPECTION

LUBRICATION

2000*(Bench Mark)

2004(Target)

Time reduction trend (All Plants)(Hours/Day)

TARGET SETTING

Hours

/D

ay

GOOD

64

11

0

25

50

75

100

2000*

(Bench Mark)

2004

(Target)

Minor stoppages (All Plants)(Th.Nos/Month)

Th.N

os

/M

on

th

GOOD

* Data recording started from Year 2000

* Data recording started from Year 2000



STEP 1 INITIAL CLEANING

! Cleaning is required to UNCOVER or DISCOVER, the Leaks, lossness, Damage,

and any other deteriorated condition of parts on the machine.

! one may be able to identify 200 to 500 defects on machines which are

revealed during cleaning :

!The defects are categorized & identified as :

1. White Tags : (Defects which can be corrected by the operator/circle

members themselves)

2. Red Tags : (Defects which require the assistance of Maintenance

personnel for correction.)

! For Deciding the correctness & ownership of Red tags a regular meeting is held

between the circle members & the maintenance personnel.


14/27




BACKGROUND

OIL LEAKAGES & COOLANT SPLASH

DUST & DIRT ON M/CS

SCATTERED CHIPS

JUMBLED WIRES



15/27




ACTIVITIES UNDER STEP 1 (INITIAL CLEANING)

Circle Leader + Circle Members

M/c Allocated : (Boring M/c No. 11) e.g.

Cleaning for Inspection & Identify Defects

Put Defect Tags (White Tags or Red Tags)

Make Matrix of all tags Category wise

Meeting for allocation of tags

White Tags Red Tags

Assign Responsibility to the Circle

Members with TDC

Assign Responsibility to Maint.

Personnel with TDC

Generate Counter measures Generate Kaizens Generate One Point lesson

Consolidate the Results as Cumulative Trend Graph (Next Page)

FLOW

CHART


ACTIVITIES UNDER STEP 1 (INITIAL CLEANING)(Contd.)

TREND GRAPH

No. of Defects No. of Kaizen No. of Breakdown Minor Stoppage


16/27



FUGUAIS

Circle members performing initial cleaning.




M/c Allocated : Boring M/c No. 11

IDENTIFY IDENTIFYConditions of Forced deterioration

In coolant,chips,slides,moving parts

Hydraulic etc.

conditions of hard to access

areas in and around the machine

Take up kaizens themes for

ImprovementDevelop One Point Lessons

Kaizen Implementation

By Circles/ Teams themselves.

ACTIVITIES UNDER STEP 2

Kaizen Implementation

By Circle/ Teams with Assistance

from PM

Consolidate & Monitor the results as Trend Graphs.

No. of kaizens No. of OPLNo.of defects

Found & ClosedNo.of Breakdown

No.of

Minor Stoppages

Eliminate/ reduce :! sources of forced deterioration

! Hard to Access Areas.FLOW

CHART


17/27



Elimination of Source of contamination

Before After

Prevent

coolant

splashing

No Guard

Localized guard

84 123142

202284

329428

497568

675

13781462 1462 1462

248332

401478

607708

1462 1462 1462

792

1243

49 1861491161010

200

400

600

800

1000

1200

1400

1600

1800

2000

Apr

00

Jul

00

Oct

00

Jan

01

Apr

01

Jul

01

Oct

01

Jan

02

Apr

02

Jul

02

Oct

02

Jan

03

Apr

03

Jul

03

Oct

03

MONTHS

NUMBERS

IDENTIFIED

RECTIFIED

GOOD

Elimination of Sources of contamination - Status(Numbers)

No coolant splashingaround the M/c.


Relayout

OfHose pipes

Improper hose

pipeProper hose pipe

265458

698

11241236

14101649

18522015

2264

34923 74 2 37 42

542

8711076 1124

12971463

17641983

2380

3 74 2 37 42

2518

362

3320

1970

400

800

1200

1600

2000

2400

2800

3200

3600

4000

4400

Apr

00

Jul

00

Oct

00

Jan

01

Apr

01

Jul

01

Oct

01

Jan

02

Apr

02

Jul

02

Oct

02

Jan

03

Apr

03

Jul

03

Oct

03

MONTHS

NUMBERS

IDENTIFIED

RECTIFIED

GOOD

Simplification of hard to access areas - Status(Numbers)

Before After



18/27




ACTIVITIES UNDER STEP 3MAKING OF TENTATIVE STANDARDS

After having completed Step 1 & Step 2 activities the operator has now, fairly

good level of knowledge and he can now set Tentative Standards for :

! Inspection

! Lubrication

! Cleaning

Based on the above activities he can also fix the standards of time, required for

each activity.

After having developed the above standards, the operator may now implement

these on his machine and observe the results, for at least 3 months.

All the machines in the plant should now reach the Step 3 level.

(Contd.)



M/c Allocated : Boring M/c No. 11

Develop Tentative Standards for

1. Inspection

2. Lubrication

3. Cleaning

Implementation for 3 Months

Paint the Machines now with a standard new colour.

At the end of Step 3 all the Machines look

Completely upgraded & wear a new look.

Next improve the surroundings of all the machines

Now a complete change of shop floor takes place.

STEP 3 FLOW CHART


19/27



ACTIVITIES UNDER STEP 3

Tentative Standard Check Sheet

Route Map

Preparation of tentative standard for cleaning, lubrication & inspection.


Marking onPressure Gauges

VISUALIZATION ON MACHINES

Marking Oil

Level

Arrow to indicateDirection of belt

rotation



20/27



155281918220718

220722442625662

266452877730474

31886

39186

48010 48694

1146714162

1672318620

213182228323494

2535827221

29590

36582

46270

8654

48694

4869446843

44389

48694

62310

15000

30000

45000

60000

75000

Jan

00

Apr

00

Jul

00

Oct

00

Jan

01

Apr

01

Jul

01

Oct

01

Jan

02

Apr

02

Jul

02

Oct

02

Jan

03

Apr

03

Jul

03

Oct

03

MONTHS

FOUND

CLOSED

1266112661

16436

16436

4802

4802

3828

3828 2176

2176

50365036

37553755

4869448694

0

10000

20000

30000

40000

50000

(NUMBERS).

Minor Flaws Unfulfilled

basic

condittions

Inaccessible

Places

ontamination

sources

Source of

quality

defectd

Unnecessary

items

unsafe places Total

Fuguai classification(Numbers)

Defects trend (Upto step 3)(Numbers)

(AS ON 30.6.04)

1266112661

16436

16436

48024802

38283828 2176 2176

50365036

37553755

4869448694

0

10000

20000

30000

40000

50000

Mi no r F la ws U nf ul fi ll ed

basic

condittions

Inaccessible

Places

Contamination

sources

Source of

quality

defectd

Unnecessary

items

unsafe places Total

Defects classification (Upto step 3)(Numbers)

Num

bers

Num

bers GOOD



ACTIVITIES UNDER STEP 4 (GENERAL INSPECTION)

In Step 4, thorough knowledge and Training is given to the operators, to

upgrade their knowledge and Maintenance skill.

With the assistance of In house teams of experts and maintenance heads,

various basic course modules are developed on different topics such as :

! Nut & Bolts

! Lubrication

!Hydraulic

!Pneumatic

!Drive

!Electric

!Safety

!Machining Condition

(Contd.)


21/27




A structured Programme for imparting this knowledge & Training to all the

employees, is drawn out & training implemented.

At the end of Step 4, there is a radical improvement in the attitude of the

operators, due to enhanced knowledge and skill levels.

(Contd.)

After these modules are developed, these are reviewed by a common

core committee & then finalized for issue & Training.


Develop 8 Technical Modules

Imparting Training on 8 Tech modules to all employee

Reexamine the machines & Equipment with higher knowledge

& skill achieved under Step - 4

Now find more defects on the machines.

Updating the standards (Developed in Step 3)

Implement the new standards for 3 months

Consolidate & monitor the progress through following parameter

No. of

New kaizens

No. of new

defects

No. of new

One Point Lesson

STEP 4 FLOW CHART


22/27



Class room trainingCut models

Training modules preparation and implementation


Example of General Inspection.

Inspection on Belt Inspection on Coupling



23/27



1803

10080

1148312277

13248 13292 13323

7571

9529

10451

12329 12382 12431

175

0

2000

4000

6000

8000

10000

12000

14000

16000

Jun' 03 Sep' 03 Dec' 03 Mar' 04 Jun' 04 Sep' 04 Dec' 04

NUMBERS

FOUND

CLOSEDTrend of new Defects (in step 4)

(Numbers)

GOOD


8933

1199 1023

480 627883

104 74

959 913

399 581851

100 65

8563

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

4.1

Nut & Bolts

4.2

Lubrication

4.5

Drives4.3

Hydraulic

4.4

Pneumatic

4.6

Electrical

4.7

Safety

4.8

Machining

Condition

(Number of defects)

Status of defects classification under step 4

FOUND - 13323

CLOSED - 12431

(AS ON 31.12.04)

NU

MBERS


Defects


24/27



4.5 4.6 4.7STEP-1

STEP WISE STATUS OF ALL CIRCLES

10TOOL ROOM

49RING PLANT

25RING FDY.

55PISTON PLANT

23AL.FDY.

18E.V.FORGE

18PIN PLANT

32E.V.M/C

12PAW

4.84.44.34.24.1

STEP - 4STEP-3STEP-2

ALLCIRCLES

PLANT

STEP WISE STATUS OF ALL CIRCLES

(AS ON 30.6.04) Completed


486889

12511648

20152411

26802951

31493358

3657

4905

5941

66956989

7318 74267516 7667

7714

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

Jan

00

Apr

00

Jul

00

Oct

00

Jan

01

Apr

01

Jul

01

Oct

01

Jan

02

Apr

02

Jul

02

Oct

02

Jan

03

Apr

03

Jul

03

Oct

03

Jan

04

Apr

04

Jul

04

Oct'

04

MONTHS

NUMBERS

(Number of Kaizens)(upto step-4)

6. KAIZEN TREND - OVERALL

CHAPTER-5 JISHU HOZEN ACTIVITY

GOOD

SLIDE NO. 46


25/27



Example - Elimination of Minor Stoppages

KK JH QM PM SHE OTPM IC ET

KAIZEN SHEET P Q C D S M

Plant: PISTON PLANT Machine Name: PRE OVAL TURNING Machine No: 110

Ka izen theme: Elimina tio n o f Mino r Sto ppa ge . Idea: Modif ied the leng th o f rocker arm to acco ma date.

Phenomna : Frequent adjustment required in the length of rocker arm small dia pistons

Problem/prese nt s ta tus : C ounterme as ure : Be nch mark 360 NOS.

Target ZERO

Kaize n s tart N OV' 03

Ka izen finish DEC' 0 3

(words / sketch) (words / sketch) Team members: MR.VIKASH KUMAR

MR.PRADEEP SRIVASTWA

MR.BABLI

MR.MAHIPAL

Benefits:

PRODUCTIVITY INCREASED BY 4 % IN SOME

Analysis: Results: PISTON MODEL.Minor stoppage occur 4- 5 times in a shift. Minor stoppage reduced.

Totaling time (360 nos/Month)

Pressure on rocker arm disturbed. Scope & Plan for Horizontal Deployment

S.No.

Spacer used in rocker arm assembly insome small dia models. - - - -

Inedequate length of rocker arm.

TDC Responsibility Status

Activity

Result

Area

-

TPM/STD/12

REVISION NO.-00

Machine

No.

Why

Why

Why

Nos/Month

Before After

360

0


ONE POINT LESSON TREND - OVERALL

100 198279

468 546623 713

792 872967 1008

1306

1768

2201

29113131 3218

3379

171 172 175 177 182 209354 375

442 540569 613

722

64 118157 168 370

336325

285254230139906461514945311862 380

400

800

1200

1600

2000

2400

2800

3200

3600

Jan

00

Apr

00

Jul

00

Oct

00

Jan

01

Apr

01

Jul

01

Oct

01

Jan

02

Apr

02

Jul

02

Oct

02

Jan

03

Apr

03

Jul

03

Oct

03

Jan

04

Dec

04

MONTHS

NUMBERS

BASIC KNOWLEDGE

IMPROVEMENT CASES

TROUBLE CASES

(Category wise One point lessons)(Upto Step - 4)

GOOD

109 226361

617 741836 933

1015 11081209 1280

1843

2354

2830

3638

3996 41234362

0

500

1000

1500

2000

2500

3000

3500

4000

4500

Jan

00

Apr

00

Jul

00

Oct

00

Jan

01

Apr

01

Jul

01

Oct

01

Jan

02

Apr

02

Jul

02

Oct

02

Jan

03

Apr

03

Jul

03

Oct

03

Jan

04

MONTHS

NUMBERS

(Number of one point lesson)

(Upto Step - 4)

Dec

04

GOOD



26/27



622

195

388

234

183

9472 64

7235 29

31

0

100

200

300

400

500

600

700

1ST

PHASE

2ND

PHASE

3RD

PHASE

CLEANING

INSPECTION

LUBRICATION

Time reduction trend(Hours/Day)

(As on 31.12.04)

TANGIBLE RESULT

Minor stoppages(Nos./Month)

2000

Benchmark

NOS./

MONTH

GOOD

2000

(Benchmark)

RESULTS

64

56

4946

3933

23

2018

17

1511

0

25

50

75

100

Oct' 02 Jan ' 03 Apr' 03 Ju l' 03 Oct' 03 Jan ' 04 Apr'04 Jul '04 Oct'04 Dec '04

Minor stoppages(Th. Nos./Month)

2000

(Benchmark)

2004

(Target)

Th.

Nos./MONTH

Hours

/Da

y

GOOD77 %Reduction


100

183218

475

648

720

167

380

0

200

400

600

800

1000

RESULTS

" Breakdown Frequency - Trend

GOOD

BREAK

DOWNNUMBERS/

MONTH

PERIOD

77 %

Reduction

2000 2001 2002

Breakdown Frequency - Trend

1999(Bench Mark)

2003 2004(Target)

2004(Jun 04)

CHAPTER-6 PLANNED MAINTENANCE ACTIVITY SLIDE NO. 50 TPM REPORT PAGE NO. 114

2004(Nov 04)

75 %

Reduction


27/27


Improvement in operatorsAttitude

Active participation / Team work

Neat and clean shop floor

INTANGIBLE RESULTS


END OF PRESENTATION

03 shrirampistons&ringsltd

Documents