Jishu Hozen Activities

Jishu Hozen Steps
Step 1 - Initial Cleaning Step 5 – Autonomous Inspection Step 2 – Countermeasures against Sources of contamination Step 6 – Standardization & Hard to access areas Step 3 – Preparing tentative standards Step 7 – Autonomous Management Step 4 - General inspection Step 1 2 3 one set of steps. From step 4, quantum jump in level. After thorough step 4, go to step 5. Otherwise you falter in step 5. Implementation of Step 1 in part 1 All Product units started Jishu Hozen step 1 activity. Kobetsu Kaizen sub committee classified machines into “A, B & C” rank. Jishu Hozen sub committee concentrated on “A” rank and few “B” rank machines for break down, defect, accident reduction & to increase the availability and reduce cost. Team of workmen and officers were involved in the initial cleaning. During cleaning, abnormalities were identified & tags were attached. Tags were classified into red & white, red tags are removed by the plant maintenance & white tags were rectified by Jishu Hozen team members.
Clea ning of Ma chine by tea m T g Identifica tion a Cla ssifica tion of ta gs in Red & White S EP 1 T Prepa re T g ma trix a Identifica tion of source of contimina tion Identifica tion of Difficult to CLI Step 1 implementation Implementation of Step 2 in part 1 Red and white fuguai were removed in Jishu Hozen Step2. Countermeasures were taken against the sources of contamination by providing localized guards, arresting leakages and horizontally deployed in all other areas. Countermeasures were taken against difficult to clean, lubricate and inspection areas, thus the Jishu Hozen activity time for cleaning, lubrication and inspection is reduced and machines remains clean without cleaning.
C ountermeasures against fuguais ST 2 EP C ountermeasures against source of contamination C ountermeasures against hard to access areas for C LI

Step 2 Implementation Implementation of Step 3 in part 1 Tentative standards were prepared for Cleaning, Inspection & Lubrication. Following colour codes & symbols were developed for carrying out the activity & indicating its frequency.
C reate tentative standards for C LI Route map marking around the machine ST 3 EP Preparation of C LI check sheet Implementation of visuals

Step 3 Implementation Figure 5.3 Step 1 implementation

Basic A pproach not Consolidated A ctivities restricted to only selected manufacturing areas C hange visible on Equipment but no change in people ST 6 EP ST 5 EP ST 4 EP DRY FLOOR ST 3 EP ST 3 EP ST 2 EP ST 1 EP PART1 PART2 Reversal DRY FLOOR ST 2 EP DRY FLOOR ST 1 EP ST 7 EP Ac tivities with Empha sis on fundamentals for a strong foundation Jishu Hozen steps Wider implementation Machines = 406. A C T IV ITY C LE A N IN G (B L A C K ) IN S P E C T IO N (O R A N G E ) D A IL Y W EEKLY M ON THLY Q UAR TERLY Visuals are implemented on the machines for ease of inspection like marking of lubrication / hydraulic oil level.S ta n d ard co lo u r co d e s y m b o ls . belt direction. Support function = 0 Jishu Hozen circles = 0 Machines = 646.1 T J IS HOZ ACT IES HU EN IVIT COVERAGE C Rank 30 %M/C S es tor 100 % PART . oil tank colour coding. pipe line colour coding. Operators = 1020 Assy stages = 0. motor RPM direction. Support function = 19 Jishu Hozen circles = 161 Oper or at s 55 % A Rank M/C 100 % A Rank M/C 100 % B Rank M/C 60 % Oper ator s 100 % BR ank M/C 100 % S es tor 0% PAR .2 J IS HOZ ACT IES HU EN IVIT COVERAGE C Rank M/C 100% Maintenance 0% Inspection Ar ea 0% Assembly Ar ea 0% Maintenance 100 % Assembly Ar ea 100 % Inspection Ar ea 100 % Wider implementation of Jishu Hozen 2 . L U B R IC A TIO N (B R O W N ) Activities under Part 2 To restore JISHU HOZEN activity. we developed ‘Dry Floor Steps 1. 2 & 3’ apart from the regular JIPM Steps. Operators = 1986 Assy stages =39.

Plant Head V. P. 3 . Unit heads. Each circle ideally should contain 8 to 10 persons. Officers and Operators. While forming the circle please keep organization in mind.Focus on Circle up gradation concept MY MACHINE CONCEPT MY CIR E CONCEPT CL A ctivity Board C ircle Meetin g Jishu Hozen concept Organization Chart & Circle formation All equipment & all people are involved. Equipment approach is not wrong. Manufactur ing Axle PU Body PU Engine PU Foundry PU T MPU Vehicle PU PU Manager QA Maintene nc e Manufa ct uring Assembly Stores Module Manager C ell 1 Cell 2 Cell 3 Cell 4 Cell L eader Circle 1 Circ le 2 Circle 3 Circ le 4 Circ le 5 C irc le 6 Cir cle Leader s Organization Chart & Circle Formation TPM is a system of overlapping circles. It is the organization that owns it. In a circle you have circle leader and member. and Module managers. TPM organization was formed consisting of Plant head. No of equipment & No of persons should be balanced. Purpose is to groom the circle leader to do the work. But equipment does not change on its own. Product unit heads. Each circle was allocated multiple numbers of equipments.

We say cleaning is inspection. In JH stagnation comes if step 1 not thorough. Don’t stick things directly on machines/walls/doors etc. Initially everyday m/c becomes dirty after cleaning of previous day.Initial Cleaning (IC) It is not just cleaning. 5 Don’t on the Shop Floor: 1. better the step 2. So this is very important. b) Identification of sources of contamination & hard to access areas – this has to be done hard way. IC means restoration of ignored equipment to bring to original condition. I do not want spic & span equipment. not by observation but by having folded arms. 5. Only with supervisors u can not change shop floor. Don’t keep -Material/Jigs/ Tools/Measuring Instruments/Products directly on the shop floor/equipment. Ideas come when you get involved. but step 1 leads to step 2. That takes you to step 2. Link with step 2. Don’t write directly on machines/walls/doors etc. You must do something. 3. 4. JH circle need to be functional In Dry floor step 1 additional activities like daily manager round & 5 DON’T’S activities were introduced to strengthen the Jishu Hozen circle activities. Ideally yes. uniform tells the story. Don’t take the temporary countermeasures 2 Do’s on the Shop Floor: Vicinity of Equipment: 1) Fix position 2) Fix quantity Excess must go out (Tools/Jigs/Material/Products/WIP) 4 . When you do the manager model. Your machine needs initial cleaning. Cleaning time becomes zero only when your sources of contamination becomes zero.superficial cleaning no good. Only functional cleaning of the equipment helps in finding out fuguai. More effort in step 1. Purpose is functional cleaning. 2. IC is to find fuguai a) Functional cleaning . Textbook says source of contamination in step 2. Don’t keep Material/Jigs/ Tools/Measuring Instruments/Products directly on the shop floor.Implementation of Dry floor steps at manufacturing shop D ry flo o r p la n t D ry flo o r sh o pCs irc le m e e t in A c t iv it y b o a rd O P L'S gs D ry flo o r ste p 1 D ry flo o r ste p 2 D ry flo o r ste p 3 S o u rc e s o f Te n t a t iv e C la ssific a t io n E a sy t o C a p tu rin g M a na ger c o n t a m in a Lei a k a g e s t st a n d a rd s fo r V isu a ls 5 D O N 'TS o f 7 t y p e s o f a c c e ss t h e lo sse s ro u n d on C IL ta g s Concept of Dry floor steps Activities for Dry Floor Step 1: Re. Continue cleaning till sources of contamination become zero. Fuguai classification is done to prioritize the fuguai removal.

. 3 D ) on't wr dir ite ectly on Machine.DyF r loorSep 1 t Equipm ent Initial Cleaning D aily Manager Round Fuguai Identification 5D on’t's Fuguai Clas ification s F uguai Rectification 5D ’t on 's 1 D ) on't k eep Mater on S ial hop Floor 2 D ) on’t K eep Mater ial r andm oly. Suppose nut / bolt loose – you think deviation from basic condition. (Meant for JH circles – teach them) Dry floor step 1 implementation Fo un d Re ctif ied Minor Defect Basic Condition Source of Contaminat ion Hard to Access Quality Defect Unnecessar y Unsafe Point How to identify which type of fuguai is it? For this you always start from the right hand side as shown by the arrow. it will fall under safety point.Machine . Let’s consider the example of screw missing at any point. 5 . . Same for other types also.Walls& D s oor 5 D ) on't tak tem ar e por y counter . By considering this you just think. eas es F g ai Clas if uu s icat ion 1 U afe places ) ns 2 U ) nwanted / S low m oving 3 Quality defect ) 4 Har to acces ) d s 5 S cesof Contam ) our ination 6 B ic Condition ) as 7 Minor defects ) .. Start from RHS. . Then remove.Walls& D s oor 4 D ) on't s tick thingsdir ectly on .. Is the missing screw unnecessary? If the answer is yes then classify the abnormality (Fuguai) in Unnecessary other wise ask the question -Is the missing screw causing quality defect? If the answer is yes then categorize it as quality defect other wise ask the next question. If any safety hazard due to loosening. It may also fall under unwanted/unnecessary. Don’t do that. Fuguai classification & Approach towards fuguai In Phase-II fuguai classification was done as follows for prioritizing the fuguai removal.m ur . can the screw missing cause unsafe condition? If the answer from this is yes than this fuguai belongs to unsafe point other wise ask the same question for unnecessary items.

One Point Lessons One Point Lessons are imparted to JISHU HOZEN Circle members for .If there is some quality problem. sputters. Only then machine changes. Even the product can be a source of contamination. steam. Suppose chips falling due to loosening then source of contamination. Noise. oil soaked water. Coolant. Learn from them. If it does not fall under any of six condition then under minor defect. Sum up these through Kaizen example sheet / OPL (generated thru CLI reduction) Normally machine cleaning of 15 hours/man/month is required. it could be under quality defect. water/air leakage. paint sludge. Oil. For step 3. Particularly for manager model. Dust. Identify all sources of contamination. stop. To achieve & sustain leakage free equipment.Trouble Cases : Points of improvement concept / method leading to positive results O eP in L s o n o t es n B ic K as now ledge Im ov ent Cas pr em es Tou r ble Cas es One point Lesson Activities for Dry floor Step 2: Kaizen/Countermeasures for contamination/Leak free & Easy to access equipment Reduction of C L I time is key parameter. people etc. Bolt/nut generally basic condition. less time required. ds platfor s& m ladder s (I)Arresting Sources of Contamination Sources of Contamination: Dry floor step 2 approach Chips. Humidity. 6 . fumes/ smoke. Dropping of product should not happen. the following approach is used: DyF o Se 2 r lo r t p Contam ination F ee E r quipm ent L eak age F ee E r quipm ent R eduction of Contam inant Gener ation L ocalis the ing Contam inant E ination of lim Contam inants P ovis r ion of Guar to ar es ds r t s plas hesof Oil & Coolant Modification of Pr s e/D ectio es ur ir n of Oil/Coolant Conver ion of s F ible H esto lex os Per anent m Metallic Pipes D ifficult to A cces s R elocation of elem ent R outing of er pipes/ cables Modification of guar .Basic Knowledge: Points that must be known . It was loose because it was hard to access. Fuguai removal is done as per the priority of Fuguai classification. Some team good change in 10 hours. If manager model > 20 hours but no perceptible change then they are losing time somewhere. In sugar factory sugar itself can be a contaminant.Improvement Cases: Point that prevents the recurrence of troubles . spray. Sand. If it falls under one condition.

b y c utting c hu te s. minimize it wherever it involves high cost.in principle. Empty it every day If you do that. put it close to source.Kobetsu Kaizen teams consisting of manufacturing. Follow this approach. That will not do. Countermeasures against source of contaminations were taken by applying the methodology to contain the source of contamination. Localization of the contaminant was done. Contaminants wise action plan was prepared to arrest the source of contamination EVERY DAY Sourc e of c ontamination reduc tion EMPTY IT C h ip s O il / C oo la nt Sa nd Red u c tion in ma c hinin g stoc k Use of loc a lise d gu a rd s De sig n c h a ng e Pro visio n lo c a lise d gu a rd s Use of Se a lin g of Use o f d ust O p timisa ti Use o f Pro visio n o f gua rd s a t o p e nin gs e xtra c tio n on of c olle c tio n skirtin g on d isc ha rg e in sa nd system a t d ire c tion & tra ys c o nveyors e nd o f c on ve ying g e ne ra tio n p re ssure c on ve yors syste m p o ints O p timisa ti on o f c oo la nt flo w W orn o ut d ie surfa c e re c o n d itio nin g Pro visio n o f trollie s to c o llec t sp illed sa n d c o nve yors b e lt w id th inc re a se d to 800 mm from 550 C o lle c tio n Re d uc tio n of c hip s b y of c h ip size using tra ys. tro llie s to ol a ngle mo d ific a ti Pro c e ss c ha n ge fro m w e t to d ry c uttin g Actions for source of contamination (II) Leakage Free Equipment To achieve the leakage free equipment Elimination. I saw very big collection pan & almost full. L ocaliz e Methodology to contain the source of contamination Put S No. you’ll know lesser or more than previous day. maintenance were formed to help Jishu Hozen to eliminate Source of contamination. no. improvement cell. Put S. Can I elim inate the s ce? our Collec Minim e iz Oil leakage. Don’t provide huge collection pan. If not possible (rare). Put a visual control mark. Don’t come straight to collection. Minimization. Then why why. lub rica nt tanks Reloc a tion of oil / lubric ant nozzles Optimisation of pressure of oil / lubric a nts Use of loc alised guards Use of gua rds with c ollection trays Use of guards with c ollec ting duc ts Actions for leakage free equipments 7 . Collection – If leakage from top. L eakage Fr Equipment ee Conversion of Flexible Hoses to Perma nent Metallic Pipes Modific ation of Pressure/ Direction of Oil/C oola nt Provision of Gua rds to arrest splashes of Oil & Coola nt Hose pip es rerouting with rigd cla mping Use of sea la nts for fittings Reduc tion of extra length pipes Reloc ation of c oola nt.eliminate it.

Lubrication and Inspection T entative standards. Lubrication. Inspection & re-tightening. Lubrication. . Activities for Hard to Access area Hard to Access Areas means: Difficult to lubricate Difficult to inspect Difficult to clean Difficult to retighten Difficult to operate JH is not only for maintenance of machine but also for operation of it.Tentative standard 2. Hard to access Easy to access for cleaning Esay to access for Inspection Easy to access for Lubrication Re routing of pipes / cables Modificatio n of platforms Removal of unwanted / big guards Relocation of gauges Implementa tion of visuals Relocation of lubricating units Rerouting of pipping Use of plain conduit inplace of spiral Provision of ladders / stair case Relocation of lubricating units Modification of filling caps Activities for Dry Floor Step 3 – Preparing Tentative Standards for Contaminant/Leakage free equipment With the help of Planned Standars Maintenance & Machine manuals. Tentative Cleaning. Dr y F loor Sep 3 t CILCheck Sheet Route Map Hydraulic power Visuals F CL or I Cleaning Daily Cleaning Weekly Cleaning Monthly Ins pection Daily Ins pection Weekly Ins pection Monthly Lubrication Daily Lubrication Monthly Cleaning 1.III.Route map Lubrication Weekly 6 Blow plate lifter pack 7 4 Situated on platform 4 Machine column Hydraul ic valve 5 3 Lubrication part Left hand Right hand part Inspection 2 Electr ical contr ol panel 1 Dry floor Step 3 implementation 8 For each of these (C L I) a set of three required. Even set up /adjustment comes under it.Check sheet 3. Counter measures against Hard to access areas for cleaning. check-sheets & route maps are developed by operators for daily Cleaning. Inspection and retightening are Identified and Rectified.

with the eye of an “operator skillful with equipment”. Audit (80%) Next Sub Step9 . Check sheet is for filling up. functions & principles of the equipment & to study its ideal state.4 Pneumatics New things will get Education on General 4. Only mechanical checking will not do. ok but if always in green. Standard is for understanding. Actual implementation by JH. then not ok. whether flow enough. If fan is moving or not seeing that is enough. This reflects on your activity. The sequence is important. Top Mgt. These training manuals will be created by E & T. Actual Implementation of Self Audit General Inspection Thus 2 pillars are involved Methodology of step 4 implementation Manual Manager Audit (85%) (90%). Inspection Capturing Minor Stoppages.3 Lubrication Rectification/ Kaizen for fuguais 4. NG Understanding Step 4 activities – General Inspection thru test In step 4 we aim to understand the structure.2 Drives 4. paper Fan Education on General Loss is generated when equipment stops for less than 15 minutes & machine component is not replaced. Make Std/ check sheet. how high it is flying.6 Electrical & Electronics correction in hand.You don’t carry standard all the time. If It R G R oil level green. Step 3 also visual Control. Do such ingenious ideas. When you teach operators to see oil level. same level. tell them to monitor if it is going down or not. ball. There are 2 parts of step 4 for implementations as Summary shown here.5 Hydraulics Revision of Inspection added. 4. Counter Measures are taken by the JISHU HOZEN circle members to reduce Minor Stoppages. Aim to inspect all constituent mechanisms & parts of the equipment. Go a step further. must go down otherwise it is not functioning. incidents have beenLeadersby the JISHU HOZEN Circle members to improve performance done Minor Stoppages rating & OEE. Visual control help you to certain extent but you need to bring ingenious ideas in that. In training modules are prepared to enhance the member skill & knowledge of circle members. to seek the ok utmost improvement in the efficiency of equipment. Leader to Circle without exception.1 Nut & Bolt Inspection 4. There are 6 sub steps: General 4.

Now education & training and review of standards / check-sheets / route-maps and the same need to be updated in step 4.g. Include new items in red. JH Implementation at Assembly line Step 1 Activities -Initial Cleaning 10 . In step 4 many many new fuguai will come to light.further changes are required. Nuts and bolts rusty. Combined final standard as against one standard/check sheet/route map for each of C L I. without washer. Step 5: You have tentative standard + check sheet + maps corrected in step 4. missing etc and review tentative standards created so far. It is a good idea to plot the number of corrected standards (C L I ) against sub steps of step 4. Summary of Results: e. In step 5 these standards get converted into final standard. Remove / cross points as applicable.g. After education & training .Teach what kind of fuguais can be present. Till step 3 emphasis was on 5 senses and not on education & training. Categorize them e. Content wise step 4 fuguai has to be much deeper. In step 5. Most important are tentative standard and check sheet. How many nuts and bolts together for inspection? How many fuguais identified. Use red colour for wrong check point. Set of OPLs required.

stretching & turning Countermeasures for moving heavy objects Eliminate double handling & inspection of parts S EP 2 T First in first out for parts Poka Yoke to reduce defects Reduce time required for counting of parts S torage place for removed packing materials Counter measures are taken against sources of contamination. and turning of body & to reduce the time required for counting parts. Storage place for non confirmative parts are provided. for moving heavy objects. boxes. tools & Jigs are done. tools & Jigs Identification & removal of unwanted & slowmoving objects STEP 1 Provision of area for non confirming parts Implementation of displays Identification & rectification of fuguais Assy Step 1 implementation During initial cleaning waste. stain marks & dust are removed. boxes. for elimination of operations involving bending. Placement of tools in such a way that double handling/Inspection eliminated by introduction of easy to pick tools.Removal of waste.stain marks & dust Arrangement of shelves. Visual controls are implemented. ease of use of Jigs.Slow moving. Fuguai’s were identified and rectified. First In First Out for parts is started.Countermeasures against Sources of Contamination & Difficult to access Countermeasures against bending . unwanted objects are identified and removed from the area.work table. worktables. Step 2 Activities . stretching. Assy Step 2 implementation Step 3 Activities – Creation of Tentative standards 11 . Arrangement of Shelves. Tools.

3 4. OPL JISHU HOZEN CIRCLE ACTIVITY STATUS Unit Cell Circl e Nam e Dry Floor Plant Step 1 Date of passi ng Step 4 4. circle passes. • TOTAL Activity TIME. Data Required for JH: 1.1 4. confirmation of parts by visual Review of w ork standards Review of setup & adjustement Assy Step 3 implementation parts were eliminated. 6 Ste p5 Ste p2 Ste p3 Ste p1 Ste p2 Ste p3 Axl e PU Pinio n Cell One circle in charge of multiple machines.) 12 . Criteria for passing some machine –individual audit.By implementation of visual controls non value added activities like searching.when all equipments pass. Thrust given on implementation of cleaning. 5 4. Inspection & Lubrication standards. • Activity Time per person(Avg. searching. Reduction of losses like set up & adjustment is carried out. Activity Time on JH Circles. counting & confirmation of STEP – 4: General Inspection 4-1 : Jigs & Tools used in Assembly 4-2 : Measuring Instruments 4-3 : Online Inspection 4-4 : Devices used in Assembly Line 4-5 : Operability / Sustainability STEP – 5: Line Balancing STEP – 6: Autonomous Control 3 treasures of JH: 1. and Visual controls implementation on assembly stages .2 4. Activity board 3.4 4.T entative standards for C IL C IL time reduction Implementation of Visual C ontrols ST 3 EP Eliminintation of counting. Meeting 2.

2. No. change comes visible. OEE Data (compilation by KK) • Loss DATA • Minor stoppage 5. No. 13 . 4hrs× 1. No. 2hrsx 3. you can have for concentrated JH in addition to daily 20 minutes.By Experience. Distribution of time is also important. 20 minutes are not enough for functional cleaning. 15 hours/person /month required. OF KAIZEN EXAMPLE SHEETS 7. 20 minutes they may or may not work. Conversion of RED to WHITE TAGS 3. Sources of Contamination 4. Additional cleaning say 2 Hrs at a time required for thorough Cleaning. One Point LESSON SHEETS 6. of DI FFICULT to ACCESS AREAS DETECTED & RESOLVED. of Fuguais DETECTED & RESOLVED • 7 Classification of Fuguais • RED & WHITE tags.

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