66362291 autonomous maintenance

Tpm.training

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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

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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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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Tpm.training

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.

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


Tools used for cleaning

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Wire brush


Spanners

To tighten loose bolts & nuts


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Showel

To clean big burr & swarf

Screw drivers

To tighten loose screws


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Allen Keys

To remove screws


Allen Keys

To remove hard/ solidified burr & dust

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Jishu Hozen 7 Steps


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

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

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

Tpm.training

Jishu Hozen 7 Steps


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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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.

Tpm.training

Tpm.training

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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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.)

Tpm.training

Tpm.training

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

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

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


coolant motors Daily 30 Oper Inform

supervisor


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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4. Overall

Inspection

Training in check-up skills

through checkup manuals.

Find and restore slight

defects through general

inspection.

Tpm.training

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

Tpm.training TVS-SUZUKI

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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.

Tpm.training


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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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 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

66362291 autonomous maintenance

Documents

training tpm

training of operators

soc tpm

training showel

training safety

training jishu hozen

self tpm

supervisors tpm