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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 a g Identifica tion Cla ssifica tion of ta gs in Red & White S T EP 1 Prepa re T a g ma trix 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 EP 2 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 EP 3 Preparation of C LI check sheet Implementation of visuals

Step 3 Implementation Figure 5.3 Step 1 implementation

S ta n d ard co lo u r co d e s y m b o ls .
IN S P E C T IO N (O R A N G E )





Visuals are implemented on the machines for ease of inspection like marking of lubrication / hydraulic oil level, motor RPM direction, belt direction, oil tank colour coding, pipe line colour coding.


Activities under Part 2

To restore JISHU HOZEN activity, we developed Dry Floor Steps 1, 2 & 3 apart from the regular JIPM Steps.

Basic A pproach not Consolidated A ctivities restricted to only selected manufacturing areas

C hange visible on Equipment but no change in people



Ac tivities with Empha sis on fundamentals for a strong foundation

Jishu Hozen steps

Wider implementation
Machines = 406, Operators = 1020 Assy stages = 0, Support function = 0 Jishu Hozen circles = 0 Machines = 646, Operators = 1986 Assy stages =39, Support function = 19 Jishu Hozen circles = 161

Oper at or 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 tor es 0%


C Rank 30 %M/C

S tor es 100 %


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

Focus on Circle up gradation concept


MY CIR CL E CONCEPT A ctivity Board

C ircle Meetin g

Jishu Hozen concept

Organization Chart & Circle formation

All equipment & all people are involved. Each circle was allocated multiple numbers of equipments. TPM organization was formed consisting of Plant head, Unit heads, Product unit heads, and Module managers, Officers and Operators.

Plant Head

V. P. Manufactur ing

Axle PU

Body PU

Engine PU

Foundry PU


Vehicle PU

PU Manager


Maintene nc e

Manufa ct uring



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. Equipment approach is not wrong. But equipment does not change on

its own. It is the organization that owns it.

While forming the circle please keep organization in mind. Each circle ideally should contain 8 to 10 persons. Purpose is to groom the circle leader to do the work. No of equipment & No of persons should be balanced. In a circle you have circle leader and member.

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 gc s t iv it y b o a rd O P L'S

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 Le ti a k a g e s 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- Initial Cleaning (IC)

It is not just cleaning. We say cleaning is inspection. Cleaning time becomes zero only when your sources of contamination becomes zero. IC means restoration of ignored equipment to bring to original condition. Your machine needs initial cleaning. Continue cleaning till sources of contamination become zero. IC is to find fuguai a) Functional cleaning - superficial cleaning no good. Only functional cleaning of the equipment helps in finding out fuguai. I do not want spic & span equipment. Ideally yes. Purpose is functional cleaning. When you do the manager model, uniform tells the story. Initially everyday m/c becomes dirty after cleaning of previous day. That takes you to step 2. You must do something. b) Identification of sources of contamination & hard to access areas this has to be done hard way, not by observation but by having folded arms. Ideas come when you get involved. So this is very important. Link with step 2. Textbook says source of contamination in step 2, but step 1 leads to step 2. More effort in step 1, better the step 2. In JH stagnation comes if step 1 not thorough. Only with supervisors u can not change shop floor. JH circle need to be functional In Dry floor step 1 additional activities like daily manager round & 5 DONTS activities were introduced to strengthen the Jishu Hozen circle activities. Fuguai classification is done to prioritize the fuguai removal.

5 Dont on the Shop Floor:

1. 2. 3. 4. Dont keep -Material/Jigs/ Tools/Measuring Instruments/Products directly on the shop floor/equipment. Dont keep Material/Jigs/ Tools/Measuring Instruments/Products directly on the shop floor. Dont write directly on machines/walls/doors etc. Dont stick things directly on machines/walls/doors etc.

5. Dont take the temporary countermeasures

2 Dos on the Shop Floor:

Vicinity of Equipment:
1) Fix position 2) Fix quantity Excess must go out (Tools/Jigs/Material/Products/WIP)

D r yF loorS t ep 1

Equipm ent Initial Cleaning

D aily Manager Round

Fuguai Identification

5D ont's

Fuguai Clas s ification

F uguai Rectification 5D on t 's 1 )D on't k eep Mater ial on S hop Floor 2 )D ont K eep Mater ial r andm oly. 3 )D on't wr ite dir ectly on Machine, .Walls& D oor s 4 )D on't s tick thingsdir ectly on .Machine ,Walls& D oor s 5 )D on't tak e tem por ar y counter .... .m eas ur es . F u g u ai Clas s if icat ion 1 )U ns afe places 2 ) U nwanted / S low m oving 3 ) Quality defect 4 ) Har d to acces s 5 )S our cesof Contam ination 6 )B as ic Condition 7 ) Minor defects .

Fuguai classification & Approach towards fuguai

In Phase-II fuguai classification was done as follows for prioritizing the fuguai removal. (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. Lets consider the example of screw missing at any point. By considering this you just think, 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. 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. Same for other types also. Suppose nut / bolt loose you think deviation from basic condition. Dont do that. Start from RHS. If any safety hazard due to loosening, it will fall under safety point. It may also fall under unwanted/unnecessary. Then remove.

If there is some quality problem, it could be under quality defect. It was loose because it was hard to access. Suppose chips falling due to loosening then source of contamination. If it falls under one condition, stop. If it does not fall under any of six condition then under minor defect. Bolt/nut generally basic condition.

One Point Lessons

One Point Lessons are imparted to JISHU HOZEN Circle members for - Basic Knowledge: Points that must be known - Improvement Cases: Point that prevents the recurrence of troubles

- Trouble Cases : Points of improvement concept / method leading to positive results

O n eP o in tL e s s o n

B as ic K now ledge

Im pr ov em ent Cas es

T r ou 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. Sum up these through Kaizen example sheet / OPL (generated thru CLI reduction) Normally machine cleaning of 15 hours/man/month is required. Only then machine changes. Particularly for manager model. If manager model > 20 hours but no perceptible change then they are losing time somewhere. Some team good change in 10 hours. Learn from them. For step 3, less time required. Fuguai removal is done as per the priority of Fuguai classification. To achieve & sustain leakage free equipment, the following approach is used:
D r yF lo o rS t e p2

Contam ination F r ee E quipm ent

L eak age F r ee E quipm ent

R eduction of Contam inant Gener ation

L ocalis ing the Contam inant

E lim ination of Contam inants

P r ovis ion of Guar dsto ar r es t s plas hesof Oil & Coolant

Modification of Pr es s ur e/D ir ectio n of Oil/Coolant

Conver s ion of F lex ible H os esto Per m anent Metallic Pipes

D ifficult to A cces s

R elocation of elem ent

R er outing of pipes/ cables

Modification of guar ds , platfor m s& ladder s

(I)Arresting Sources of Contamination Sources of Contamination:

Dry floor step 2 approach

Chips, Oil, Sand, Dust, Coolant, Humidity, Noise, fumes/ smoke, sputters, water/air leakage, spray, oil soaked water, paint sludge, steam, people etc. Identify all sources of contamination. Even the product can be a source of contamination. In sugar factory sugar itself can be a contaminant. Dropping of product should not happen.

Kobetsu Kaizen teams consisting of manufacturing, improvement cell, maintenance were formed to help Jishu Hozen to eliminate Source of contamination. Countermeasures against source of contaminations were taken by applying the methodology to contain the source of contamination.
Can I elim inate the s our ce?


Minim iz e

Oil leakage- in principle- eliminate it. If not possible (rare), minimize it wherever it involves high cost. Collection If leakage from top, put it close to source. Dont come straight to collection. Dont provide huge collection pan. Put a visual control mark.

L ocaliz e

Methodology to contain the source of contamination Put S No. Empty it every day

If you do that, youll know lesser or more than previous day. Then why why. I saw very big collection pan & almost full. That will not do. Follow this approach.
Put S. no.

Contaminants EVERY DAY wise action plan was prepared to arrest the source of contamination
Sourc e of c ontamination reduc tion


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, b y c utting c hu te s, 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, Minimization, Localization of the contaminant was done.
L eakage Fr ee Equipment

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, 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

III. 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. Even set up /adjustment comes under it.
Counter measures against Hard to access areas for cleaning, Lubrication, Inspection and retightening are Identified and Rectified. 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 Maintenance & Machine manuals, Tentative Cleaning, Lubrication and Inspection T entative Standars standards, check-sheets & route maps are developed by operators for daily Cleaning, Lubrication, Inspection & re-tightening.
Dr y F loor S t ep 3

CILCheck Sheet

Route Map
Hydraulic power

Visuals F or CL I Cleaning Daily Cleaning Weekly Cleaning Monthly Ins pection Daily Ins pection Weekly Ins pection Monthly Lubrication Daily Lubrication Monthly Cleaning 1.Tentative standard 2.Check sheet 3.Route map Lubrication Weekly
Blow plate lifter


7 4

Situated on platform

4 Machine column
Hydraul ic valve

Lubrication part

Left hand

Right hand part


Electr ical contr ol panel

Dry floor Step 3 implementation 8

For each of these (C L I) a set of three required.

You dont carry standard all the time. Standard is for understanding. Check sheet is for filling up.

Step 3 also visual Control.

If It

oil level green, ok but if always in green, same level, then not ok. must go down otherwise it is not functioning. When you teach operators to see oil level, tell them to monitor if it is going down or not. Only mechanical checking will not do. Visual control help you to certain extent but you need to bring ingenious ideas in that. If fan is moving or not seeing that is enough. Go a step further, ball, how high it is flying, whether flow enough. Do such ingenious ideas. This reflects on your activity.
paper Fan

Education on General Loss is generated when equipment stops for less than 15 minutes & machine component is not replaced. Inspection Capturing Minor Stoppages, incidents have beenLeaders done by the JISHU HOZEN Circle members to improve performance

Minor Stoppages
rating & OEE.

Counter Measures are taken by the JISHU HOZEN circle members to reduce Minor Stoppages.
NG Understanding Step 4 activities General Inspection thru test In step 4 we aim to understand the structure, functions & principles of the equipment & to study its ideal state, to seek the ok utmost improvement in the efficiency of equipment. Aim to inspect all constituent mechanisms & parts of the equipment, Leader to Circle without exception, with the eye of an operator skillful with equipment. In training modules are prepared to enhance the member skill & knowledge of circle members. There are 6 sub steps: General 4.1 Nut & Bolt Inspection 4.2 Drives 4.3 Lubrication Rectification/ Kaizen for fuguais 4.4 Pneumatics New things will get Education on General 4.5 Hydraulics Revision of Inspection added. Make Std/ check sheet. 4.6 Electrical & Electronics correction in hand. The sequence is important. There are 2 parts of step 4 for implementations as Summary shown here. These training manuals will be created by E & T. Actual implementation by JH. Actual Implementation of Self Audit General Inspection Thus 2 pillars are involved

Methodology of step 4 implementation

Manager Audit (85%)


Top Mgt. Audit (80%)

Next Sub Step9

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

Step 5:
You have tentative standard + check sheet + maps corrected in step 4. In step 5, Combined final standard as against one standard/check sheet/route map for each of C L I.

JH Implementation at Assembly line Step 1 Activities -Initial Cleaning


Removal of waste,stain marks & dust Arrangement of shelves, boxes,work table, 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. Arrangement of Shelves, boxes, worktables, tools & Jigs are done. Fuguais were identified and rectified.Slow moving, unwanted objects are identified and removed from the area. Storage place for non confirmative parts are provided. Visual controls are implemented.

Step 2 Activities - Countermeasures against Sources of Contamination & Difficult to access

Countermeasures against bending , stretching & turning Countermeasures for moving heavy objects Eliminate double handling & inspection of parts S T EP 2 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, for moving heavy objects, for elimination of operations involving bending, stretching, and turning of body & to reduce the time required for counting parts. Placement of tools in such a way that double handling/Inspection eliminated by introduction of easy to pick tools, ease of use of Jigs, Tools. First In First Out for parts is started.

Assy Step 2 implementation

Step 3 Activities Creation of Tentative standards


T entative standards for C IL C IL time reduction Implementation of Visual C ontrols ST EP 3 Eliminintation of counting, searching, confirmation of parts by visual Review of w ork standards Review of setup & adjustement

Assy Step 3 implementation parts were eliminated. Reduction of losses like set up & adjustment is carried out.

Thrust given on implementation of cleaning, Inspection & Lubrication standards, and Visual controls implementation on assembly stages .By implementation of visual controls non value added activities like searching, 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. Meeting 2. Activity board 3. OPL


Unit Cell Circl e Nam e Dry Floor Plant Step 1
Date of passi ng

Step 4 4.1 4.2 4.3 4.4 4. 5 4. 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. Criteria for passing some machine individual audit- when all equipments pass, circle passes.

Data Required for JH:

1. Activity Time on JH Circles. TOTAL Activity TIME. Activity Time per person(Avg.)

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