TPM

JISHU HOZEN By Sudhansu Bhushan Mohapatra TPM Consultant ± IIPM E-mail : sbm@iipm.ac.in

FOUR STEPS TO ACHIEVE JH
STEP 0 Understanding the equipment. STEP 1 Initial cleaning & abnormality identification. STEP 2 Abnormality rectification & eliminating hard to access area. STEP 3 Preparation of tentative ³ CLTI´ standards

STEP 0
This is a preparatory step, which deals with making people aware of the adverse effects of forced deterioration.

Major problem(1)

Medium problem(30)

Minor problems(300) Invisible problems(3000)

Heienrich triangle.

2. . 3. Understanding the equipment Draw single line diagram to know function of all parts and sub assemblies To understand safety requirements associated with the equipment. Understand why forced deterioration is caused and the losses due to this To provide one point lesson in all unsafe condition and in skill required for CLTI. 4.STEP 0 1.

Time delay to bring drawing from office . go and bring drawing from the drawing office Time saved and we can easily understand the equipment and its sub assemblies.Draw single line diagram to know function of all parts and sub assemblies Oh my god another breakdown.

Do not touch electrical parts with wet hands .To understand safety requirements associated with the equipment.

outer race . igure show the bearing used in our fan CAGE INNER RACE BALL OUTER RACE .rolling element ( ball )and cage . Date of preparation Group leader Prepared By Classification Bearing used in ID an is ball bearing type which consist of inner race .One point lesson ONE POINT LESSON Theme PART & TYPE OF BEARING IN ID FAN Basic Knowledge Improvement Cases Trouble Cases Section chief Chief Clerk No.

STEP 1 Initial cleaning
Prepare a cleaning plan. Thorough cleaning of the equipment and the surrounding. List out the abnormality and put a red tag near the equipment.

Prepare cleaning plan and thoroughly clean the equipment and the surrounding.

List out the abnormality and put a red tag near the equipment.

Abnormal temperatur e

Abnormal smell

Abnormal vibration leakages

. Abnormal temperatur e Abnormal smell Abnormal vibration leakages Go near the equipment and put red tags on the abnormalities found.List out the abnormality and put a red tag near the equipment.

) and to improve the areas hard to access for cleaning. lubrication and maintaining the allocated time. This step generates lots of kaizens developed by the TPM members. .STEP 2 Countermeasure for the cause of forced deterioration and improving hard to access areas This step is to eliminate the sources that generates the contaminations (dirt stains etc.

Examples of countermeasure against Source of contamination Before After .

Countermeasure against hard to access areas Before After .

Kaizen made for hard to clean area Before After .

. After this CLTI calendar to be filled. If it is not then take the action to develop a new cleaning. including the time required. oiling and retightening of the equipment parts.Preparation of tentative ³ CLTI ´ standards First understand the requirement of the operator and whether the present standard is meeting his requirement. inspection and lubrication standard for the same. In consultation with the operators and the maintenance crew. prepare a plan for cleaning. After these things are finalized the leader should assign the responsibility to the different people.

lubrication.Come up with better ideas of all Decide places for cleaning. . tightening and inspection (CLTI).

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Cleaning .

Lubrication .

Tightening .

Inspection .

Abnormal sound .

Vibration / Temperature .

Burning smell .

Make a schedule and plan for the same CLIT CALENDAR .

Pressure gauge marking Before After .

Oil level marking for better inspection Before After .

Points marked on retightening parts .

CLTI marking and direction of rotation marking Before After .

Open and close marked on the equipment After marking we can easily tell whether open or closed .

Open and close marked on the equipment Proper identification of lubricant and container No identification of lubricant and container .

Checks to be performed during normal working hours Hmm everythin g is fine .

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VALVE KEPT CLOSED IN OPERATION MATCHED MIS-MATCHED .

1 L-1 I-5 I-2 I-1 I-3 I-4 .C-1 C-4 C-3 C-2 VT PUMP-1 L-2.

these valves are painted in three different colors for easy identification.Examples of visual controls implemented for easy inspection (BLOWER AREA) A blower is having three valves. Outlet valve Inlet Valve By-pass Valve BLOWER CASING OIL PRESSURE GAUGE .

3 Stand . 2 .EXAMPLE OF VISUAL MANAGEMENT -WIRE ROD MILL -STAND 1 .3 Pressure gauges D C Motor Bevel gear box .

Visual Management TILL STEP-4 IN STEP-5 V-Belt rotation was not visible due to existing cover Transparent V belt guard provided & visual management achieved .

Before After Initial cleaning at Stand no .1 Example of Fuguai in Stand no-1 of noWire Rod Mill Countermeasure against Hard to access area -stand area of Wire Rod Mill Source of Contaminatio Water splashing at stand of WRM .

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Example .Visualisation of Inspection Point Bearing temperature monitoring of all blower at a single panel Oil flow meters are installed to ensure correct quantity of oil flow inside the monoblock with range marking Pressure gauge range marking for easy inspection .

Example of Visual control Implemented for Easy Inspection Lubricator scale marked for easy inspection .

JISHU HOZEN ICL VISHNUPURAM .

Step -1 Initial cleaning .

Step -1 Initial cleaning & abnormality listing .

Step -1 Initial cleaning & abnormality listing .

We are responsible of our equipment Jishu Hozen chairman TPM Chief Coordinator TPM coordinator Kiln Team Leader .

KILN MAINDRIVE BEFORE AFTER .

KILN MAINDRIVE BEFORE AFTER .

STEP3 ± CLTI MARKING VISUALISATION BEFORE AFTER .

STEP3 ± CLTI MARKING VISUALISATION BEFORE AFTER .

STEP3 ± CLTI MARKING VISUALISATION BEFORE AFTER .

STEP 3 ± CLTI MARKING BEFORE AFTER .

STEP 3 ± CLTI MARKING BEFORE AFTER .

STEP 3 ± CLTI MARKING BEFORE AFTER .

STEP 3 ± CLTI MARKING BEFORE BEFORE .

CLTI in Kiln-1 main drive area KilnBEFORE AFTER .

CLTI in Kiln-1 main drive area KilnBEFORE AFTER .

CLTI in Kiln-1 main drive area KilnBEFORE AFTER .

Finally conduct Audits and confirm the proper implementation of the standards .

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