66362291 autonomous maintenance
DESCRIPTION
pTRANSCRIPT
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Tpm.training
Sa
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Tpm.training
Jishu Hozen autonomous Maintenance
Purpose : 1. Training of operators to be proficient in equipment 2. Protecting ones own equipment
Members: 1. Operators 2. Line leaders 3. supervisors
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JISHU HOZEN
Jishu Hozen is the activities which
each operator performs -daily inspection ,
lubrication, parts replacement, repair,
trouble-shooting, accuracy checks and
so forth on his own equipment, aiming at
achieving the goal of keeping ones own
equipment in good condition by one self
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Tpm.training
Jishu Hozen 7 Steps
1. Initial Clean up
2. Counter Measures
3. Tentative standards
4. General Inspection
5. Autonomous Inspection
6. standardisation
7. Autonomous
Management
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Tpm.training
Jishu - Hozen Steps for developing
1. Initial
Cleaning
(inspection)
All- around clean-up of
dust and dirt on equipment.
Oiling and re-tightening of
bolts and nuts
Finding and restoration of
Fuguai (abnormalities)
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So Cleaning isESSENTIAL Purpose of cleaning
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DIS COVER ---- DISCOVER -
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WHAT TO CHECK ? Loose bolts & nuts.
Loose wires.
Missing parts.
Rusted parts.
Broken parts.
Cracked parts.
Air leaks
Oil leaks
Coolant leaks.
Dirt, dust and cobwebs.
Oil on the floor.
Scrap around the machine.
Burr and swarf around the machine.
Abnormal heat.
Abnormal sound.
Abnormal vibration.
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Tpm.training
Jishu Hozen 7 Steps
Step 1: Initial Clean up
a. Formation of JH circles b. division of machine pars to operators c. Training on abnormality identification d. Preparation of red & white tags
a. White tags for abnormality that can be corrected by unskilled person b. Red tags for abnormality that can be corrected by skilled person
e. Keeping cleaning tools ready f. fixing time for JH Activity g. Cleaning all parts of the machine even opening of parts are necessary h. Inspection of parts during cleaning activity i. Identification and tagging of abnormality and recording j. Identify difficult to access areas around the machine-In-Accessible(IA) k. Identify the SOC source of contamination after cleaning l. Record in the matrix red & white tags,IA,SOC
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Baniyan waste
To clean small burr & coolant
Nylon brush
To clean small burr & coolant
Tools used for cleaning
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Wire brush
To clean small burr & coolant
Spanners
To tighten loose bolts & nuts
Tools used for cleaning
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Showel
To clean big burr & swarf
Screw drivers
To tighten loose screws
Tools used for cleaning
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Allen Keys
To remove screws
Tools used for cleaning
Allen Keys
To remove hard/ solidified burr & dust
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Jishu Hozen 7 Steps
Step 1: Initial Clean up
a. Formation of JH circles b. division of machine pars to operators
Machine no:
Circle No:
Circle Leader:
Circle Members:
1
2
3
4
Machine Parts: Responsibility:
1
2
3
4
5
6
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Tpm.training
Jishu Hozen 7 Steps
Step 1: Initial Clean up Record in the matrix red & white tags,IA,SOC
Tag MatrixMachine No:
Circle No:
Slno M/c Parts dust Leak Loose Missing vibration noise Broken Wornout nonStd others total
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
P = Tags put R= Tags RemovedPR
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Tpm.training
Jishu Hozen 7 Steps
Step 1: Initial Clean up Record in the matrix red & white tags,IA,SOC
Source of Contaminantion
slno contaminant source Why Why why Why countermeasure
1
2
3
4
5
6
7
InAccessible /difficult to Clean,Lubricate,Inspect,Re-tighten - CLIR
slno Area CLIR Why Why why Why countermeasure
1
2
3
4
5
6
7
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Jishu Hozen 7 Steps
Step 1: Initial Clean up
Countermeasure Plan for Red/white/IA/SOC
slno abnormality Tgt Dt Resp
1
2
3
4
5
6
7
8
Action Plan
0
5
10
15
20
25
No of tags
Failure Setup Yield Defect Motion
Tags linked to losses
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Jishu - Hozen Steps for developing
2.
Countermeasure
s for sources of
problems and
difficult places
Eliminate causes for dirt
and dust.
Improve places which are
difficult to clean,
lubricate, and re-
tightening of bolts and
nuts.
Reduce time for clean-up
and oiling.
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Jishu Hozen 7 Steps
Step 2: Countermeasures for SOC/IA/others
a. Taking actions on all abnormalities b. eliminating difficult to access areas c. Eliminating SOC d. Machine CLEAN Without Cleaning status e. Various kaizens implemented f. Machine ready for tentative standard preparation g. Step2 audit passed
Tags Put Vs Removed - cumulative for HSL9
0
50
100
150
200
250
Aug-04 Sep-04 Oct-04 Nov-04 Dec-04 Jan-05
No of tags
Tags put Tags removed
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Before After
JH 2nd step
Easy to clean / Hard to access area
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Before After
JH 2nd Step
Easy to lubricate
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Before After
JH 2nd step
Easy to inspect and adjust
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Jishu - Hozen Steps for developing
3. Establishing
Tentative
Standards for
Jishu-Hozen
Make temporary
procedures or manual of
Autonomous Maintenance
for cleanup, lubrication, re-
tightening, checkups.
(Specify the time
allocation for various
maintenance daily or
regularly held.)
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Jishu Hozen 7 Steps
Step 3: Preparation of Tentative standards
a. Making a list of Cleaning, Lubrication,Inspection & Re-tigthening points b. arriving at method and frequency of CLIR c. dividing the CLIR into mahine zones d. Preparation of standards chart with visual aids e. Education of operators on standards f. Practising the standards for minimum 1 month g. Update new check points h. Have step 3 audit Passes
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Jishu Hozen 7 Steps
Step 3: Preparation of Tentative standards
JH Tentative Checksheets
MONTH : M/C NO :
SL
NO
1 2 3 4 5 6 7 8 9 10
11
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19
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21
22
23
24
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31
RUNNINGSTOPPED
1 CLEANING RUNNING STOPPED
1.1Clean front side of machine
Dy 60 Oper
1.2 Clean burrs in bed
Wk 300 Oper
1.5.Clean coolant tank
Dy 60 oper
2 INSPECTION2.1 Hyd.oil level (should be in
green band) Dy 10 Oper Top up oil
2.3 Lub.oil level
Dy 10 Oper Top up oil
Lub oil pressure(Within
green band ) Dy 10 Oper
Inform
supervisor
2.4 Hyd.system pressure
(green band) Dy 10 Oper
Inform
supervisor
2.6 Abnormal noise ,heat in
hydraulic motors Daily 30 Oper
Inform
supervisor
2.6 Abnormal noise ,heat in
coolant motors Daily 30 Oper Inform
supervisor
2.6 Abnormal noise ,heat in
lub motors Daily 30 Oper Inform
supervisor
Check lub oil pressure(within
green band) Daily 10 Oper Inform
supervisor
2.1 Cutting oil level (should
be in green band) Daily 10 Oper Inform
supervisor
RE
SP ACTION IF
ABNORMA
L
M/C
STATUS
DATE
ACTIVITY HOW
FR
EQ
TIM
E
(SE
C)
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Jishu - Hozen Steps for developing
4. Overall
Inspection
Training in check-up skills
through checkup manuals.
Find and restore slight
defects through general
inspection.
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Jishu Hozen 7 Steps
Step 4: Preparation of General Inspection
Bolts & Nuts Pneumatics Hydraulics Electrical DrivesFits/toler
ancesSafety
Process
condition
2
TopicsSl
No.Emp. No. Name M/c No
11
3
4
5
6
7
8
9
10
JH Step 4 Training
1
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Jishu - Hozen Steps for developing
5. Autonomous
Inspection
Formulation and
implementation of clean-
up and oiling lubricate
criteria and autonomous
inspection check sheet
which can be performed
efficiently and positively.
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Tpm.training
Jishu - Hozen Steps for developing
6. Standardization Standardize various types of
field management items.
Establish the system to
thoroughly maintain and
control them.
Establish logistics standard
Standardization of data records
Standardization of die, tool and
jig management
Process quality assurance
standard, etc.
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Tpm.training
Jishu - Hozen Steps for developing
7. Autonomous
Management
Continue to develop
corporate policy and
commitment target and
conduct Kaizen activities
regularly, and record the
data analyzed through
MTBF to improve the
equipment.
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Tpm.training
TPM Vs initiatives at Wada
sixsigma comm.
eff
scrap
redn d/t redn
Meas.Pri
nt
cust.Co
mpl.
Vendor
Dev. RTY Imp COQ HMP GMP Tool.Imp M/c Imp
Spares.
Mgmt Projects
1 KK
2 JH
3 QM
4 PM
5 Otpm
6 E&T
7 SHE
8 Ifc
9 Ttpm
TPM
Double E initiatives Quality Initiatives Projects