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5 6 7 8 9
Initial flow Control
Education & Training
Safety, Health & environment
Jishu Hozen – autonomous Maintenance
1. Training of operators to be proficient in equipment 2. Protecting ones own equipment
1. Operators 2. Line leaders 3. supervisors
“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 “one’s own equipment in good condition by one self ”
General Inspection 3. Counter Measures 1. Tentative standards 2. Autonomous Management 6. Initial Clean up Tpm.Jishu Hozen – 7 Steps 7. Autonomous Inspection 4.training . standardisation 5.
Initial Cleaning (inspection) • All.training .Hozen Steps for developing 1.around clean-up of dust and dirt on equipment.Jishu . • Oiling and re-tightening of bolts and nuts • Finding and restoration of “Fuguai” (abnormalities) Tpm.
Purpose of cleaning So Cleaning is…ESSENTIAL Tpm.training .
training .DIS COVER ---- DISCOVER Tpm.
Burr and swarf around the machine. Abnormal heat. Missing parts. Broken parts.WHAT TO CHECK • • • • • • • • • • • • • • • • Tpm. Rusted parts. Abnormal sound. Oil on the floor. . Scrap around the machine. Dirt. Cracked parts.training ? Loose bolts & nuts. Loose wires. Abnormal vibration. Air leaks Oil leaks Coolant leaks. dust and cobwebs.
b. g. h. l.training . j. f. c. i. k. d.IA.Jishu Hozen – 7 Steps Step 1: Initial Clean up a. Red tags – for abnormality that can be corrected by skilled person Keeping cleaning tools ready fixing time for JH Activity Cleaning all parts of the machine – even opening of parts are necessary Inspection of parts during cleaning activity Identification and tagging of abnormality and recording Identify difficult to access areas around the machine-In-Accessible(IA) Identify the SOC – source of contamination after cleaning Record in the matrix – red & white tags. Formation of JH circles division of machine pars to operators Training on abnormality identification Preparation of red & white tags a.SOC e. Tpm. White tags – for abnormality that can be corrected by unskilled person b.
Tools used for cleaning Baniyan waste To clean small burr & coolant Nylon brush To clean small burr & coolant Tpm.training .
training .Tools used for cleaning Wire brush To clean small burr & coolant Spanners To tighten loose bolts & nuts Tpm.
training .Tools used for cleaning Showel To clean big burr & swarf Screw drivers To tighten loose screws Tpm.
training .Tools used for cleaning Allen Keys To remove screws Allen Keys To remove hard/ solidified burr & dust Tpm.
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: 1 2 3 4 5 6 Responsibility: Tpm.training .
SOC Tag Matrix Machine No: Circle No: Slno M/c Parts dust 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 R P Leak Loose Missing vibration noise Broken Wornout nonStd others total P = Tags put R= Tags Removed Tpm.Jishu Hozen – 7 Steps Step 1: Initial Clean up • Record in the matrix – red & white tags.IA.training .
Lubricate.IA.Re-tighten .Jishu Hozen – 7 Steps Step 1: Initial Clean up • Record in the matrix – red & white tags.Inspect.training .CLIR slno Area 1 2 3 4 5 6 7 CLIR Why Why why Why countermeasure Tpm.SOC source Why Why why Why countermeasure Source of Contaminantion slno contaminant 1 2 3 4 5 6 7 InAccessible /difficult to Clean.
training .Jishu Hozen – 7 Steps Step 1: Initial Clean up Countermeasure Plan for Red/white/IA/SOC slno 1 2 3 4 5 6 7 8 Tags linked to losses No of tags 25 20 15 10 5 0 Failure S etup Yield Defect Motion abnormality Action Plan Tgt Dt Resp Tpm.
• Countermeasure s for sources of • problems and difficult places Eliminate causes for dirt and dust. and retightening of bolts and nuts. Improve places which are difficult to clean.training . lubricate.Jishu . Tpm.Hozen Steps for developing 2. • Reduce time for clean-up and oiling.
g. Taking actions on all abnormalities eliminating difficult to access areas Eliminating SOC Machine ‘ CLEAN Without Cleaning’ status Various kaizens implemented Machine ready for tentative standard preparation Step2 audit passed Tags Put Vs Removed . c. f.Jishu Hozen – 7 Steps Step 2: Countermeasures for SOC/IA/others a. d. b. e.cumulative for HSL9 No of tags 250 200 150 100 50 0 Aug-04 Sep-04 Oct-04 Nov-04 Dec-04 Jan-05 Tags put Tags removed Tpm.training .
JH 2nd step Easy to clean / Hard to access area Before After Tpm.training .
training .JH 2nd Step Before Easy to lubricate After Tpm.
training .JH 2nd step Easy to inspect and adjust Before After Tpm.
Jishu . retightening. Establishing • Tentative Standards for “Jishu-Hozen” Make temporary procedures or manual of Autonomous Maintenance for cleanup. checkups. • (Specify the time allocation for various maintenance daily or regularly held.training . lubrication.) Tpm.Hozen Steps for developing 3.
e. g.Jishu Hozen – 7 Steps Step 3: Preparation of Tentative standards a.training . b. c.Inspection & Re-tigthening points arriving at method and frequency of CLIR dividing the CLIR into mahine zones Preparation of standards chart with visual aids Education of operators on standards Practising the standards for minimum 1 month Update new check points Have step 3 audit Passes Tpm. Lubrication. d. Making a list of Cleaning. f. h.
3 Lub.oil level Lub oil pressure(Within green band ) 2.2 Clean burrs in bed 1.1 Cutting oil level (should be in green band) Dy Dy Dy Dy Daily Daily Daily Daily Daily 10 Oper Top up oil 10 Oper Top up oil Inform supervisor Inform 10 Oper supervisor Inform 30 Oper supervisor 10 Oper 30 Oper Inform supervisor 30 Oper Inform supervisor 10 Oper Inform supervisor 10 Oper Inform supervisor Tpm.6 Abnormal noise .6 Abnormal noise .Jishu Hozen – 7 Steps Step 3: Preparation of Tentative standards JH Tentative Checksheets MONTH : SL NO M/C STATUS RUNNING STOPPED RUNNING STOPPED M/C NO : ACTION IF ABNORMA L TIME (SEC) FREQ 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 CLEANING 1.5.1Clean front side of machine ü ü ü ü ü ü ü ü ü ü ü ü Dy Wk 60 Oper 300 Oper 1.4 Hyd.Clean coolant tank Dy 60 oper 2 INSPECTION 2.oil level (should be in green band) 2.6 Abnormal noise .system pressure (green band) 2.1 Hyd.heat in hydraulic motors 2.heat in lub motors Check lub oil pressure(within green band) 2.training 31 ACTIVITY HOW RESP DATE 1 2 3 4 5 6 7 8 9 .heat in coolant motors 2.
training .Hozen Steps for developing 4. Tpm.Jishu . Overall Inspection • Training in check-up skills through checkup manuals. • Find and restore slight defects through general inspection.
Emp.training . No.Jishu Hozen – 7 Steps Step 4: Preparation of General Inspection JH Step 4 Training Topics Sl No. Name M/c No Bolts & Nuts Pneumatics Hydraulics Electrical Drives Fits/toler ances Safety Process condition 1 2 3 4 5 6 7 8 9 10 11 Tpm.
training .TVS-SUZUKI Tpm.
Autonomous Inspection • Formulation and implementation of cleanup and oiling lubricate criteria and autonomous inspection check sheet which can be performed efficiently and positively. Tpm.training .Jishu .Hozen Steps for developing 5.
Hozen Steps for developing 6. Tpm. Establish the system to thoroughly maintain and control them. etc.training . – Establish logistics standard – Standardization of data records – Standardization of die.Jishu . tool and jig management – Process quality assurance standard. Standardization • Standardize various types of field management items.
Autonomous Management • Continue to develop corporate policy and commitment target and conduct “Kaizen” activities regularly.Hozen Steps for developing 7.training . and record the data analyzed through MTBF to improve the equipment. Tpm.Jishu .
training .TPM Vs initiatives at Wada Double E initiatives Quality Initiatives comm.Pri cust. Tool. RTY Imp COQ HMP Projects sixsigma TPM GMP Spares. Dev.Co Vendor eff redn d/t redn nt mpl. scrap Meas.Imp M/c Imp Mgmt Projects 1 2 3 4 KK JH QM PM 5 Otpm 6 7 8 E&T SHE Ifc 9 Ttpm Tpm.
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