You are on page 1of 13

5th TPM National Conference

Session B : Jishu Hozen (Autonomous Maintenance)

Topic :
JH Step 1-4

Presentation by

Mr Pravas Kumar Mohapatra Dy Manager Birla Tyres

of Plants 6 1 2 1 5 1 1 1 1 1 1 4 1 2 Total 28 01 Cement 02 Heavy 12 11 01 12 06 12 14 10 14 12 01 05 04 05 05 08 09 05 07 02 03 13 03 MDF Board 04 Paper 05 Plantation 06 Polymerisation 07 Rayon 08 Refractories 09 Spun Pipe 01 01 10 Shipping 11 Tech.000 million Employees : 40.000 5th TPM National Conference B OUT LINE OF OUR GROUP TPM Product Chemicals No. BIRLA GROUP OF COMPANIES Group Worth: Rs. 45.Birla Tyres JH Step 1-4 UP RO O G B K BIRLA GRO UP O F C O MPANIES A PRESENTATION ON "JISHU-HOZEN" BIRLA TYRES F COMPA N IR K B LA IES AREA OF BUSINESS OF B.K. Institute 12 Textile 05 13 Tyre 14 Yarn TyreCord 01 01 03 Page 4.1 .

QS – 9000 QUALITY MANAGEMENT SYSTEM (SYSTEM FOR AUTOMOBILE INDUSTRY) . of stamdards) Kaizen on hard to inspect area. Hydraulic. OSHAS-18000 & SA-8000 CERTIFICATION MARCH’92 Rs.2004 .Birla Tyres JH Step 1-4 HISTORY OF BIRLA TYRES . TURNOVER 2003 . ISO – 9001 QUALITY MANAGEMENT SYSTEM .31 MILLIONS 25 % 73 STOCK POINTS 1994 1998 1999 2000 TPM - 2001 2004 JISHU-HOZEN PROCESS 1s SEIRI 2s SEITON Model Machine and Total Floor 3s SEISO TPM STEP#0 Preparation of Jishu Hozen Master Plan Selection of Model Machine Small Group Formation Preliminary Education and Training STEP#1 Initial Cleaning Preparation of Fugai List Audit STEP#4 General Inspection Training on Modules. ISO – 14000 ENVIRONMENT MANAGEMENT SYSTEM . STEP#3 Preparation of Tentative standard for Cleaning. TPM EXCELLENCE AWARD FIRST CATEGORY . EXPORT PERCENTAGE OF PRODUCTION . BY NABL . DISTRIBUTION NETWORK ALL OVER COUNTRY . Electrical & Pneumatics etc. CERTIFICATION OF CALIBRATION LAB. Lubrication and Inspection Horizontal application of Counter measures in other Machines STEP#2 Countermeasure against Contamination Sources and Hard to access Areas Audit Audit STEP#5 Standardisation of Checks Autonomous Inspection (Rev. STARTED COMMERCIAL PRODUCTION . 7893. Nut & Bolts. Transmission.2 . Audit STEP#6 Preparation of Jishu Hozen Calender for Machine Audit 5th TPM National Conference Page 4.

I/c. Maint. Cleaned A1 Passenger Tyre Curing Press. Un-necessary items. Leakages. Why why analysis of causes of forced deterioration ( Hard to access & Sources of Contamination Countermeasure Plan for Hard to access areas and Sources of Contamination among group members (Optr. White tags are attached to abnormalities which can be taken care of by Operators.I/c) Implementation of Countermeasures and Visual Controls Horizontal deployment plan for Countermeasures 5th TPM National Conference Page 4. Loose Parts.3 .. JISHU HOZEN STEP-2 PROCESS: Analysis of Abnormalities detected during initial cleaning TPM Rectification of Abnormalities on Machine line. Red tags are attached to abnormalities which can not be taken care of by Operators. Missing parts etc.Birla Tyres JH Step 1-4 JISHU HOZEN STEP-1 (EXAMPLE) Step .1 : Initial Cleaning Example: Before After TPM Dirty A-1 Passenger Tyre Curing Press. Prodn.

BEFORE AFTER TPM CLEANING OF SPLICE PRESS HOSE PIPE DIFFICULT DUE TO FIXED COVER. Poor light arrangement. Solenoid Clean and Station Corners TPM Machine : TBM-M9 Analysis Why 2 Why 3 Cause Countermeasure Countermeasure In-Built design. Dust and dirt on Servicer Assy. Head Stock Main Motor gear Metallic cover To protect Assy. Tube light to be provided from both the sides. CLEANING TIME REDUCED FROM 25 MIN. Head Stock Assembly.hard and belt to inspect. main motor Station belt drive . FRL Unit. Less illumination. Poor Design. Head Stock Assembly. Detachable cover with handle to be provided for easy handling. Servicer Assembly.Birla Tyres JH Step 1-4 EXAMPLE OF COUNTERMEASURE FOR CAUSE OF FORCED DETERIORATION Phenemonen Where What Why 1 Head Stock Solenoid hard to Sharp edges Assy. Lack of Lubrication. Cover is fixed with bolts. PER WEEK. provided in place of metallic cover for easy inspection. 5th TPM National Conference Page 4. HINGED COVER PROVIDED. from dust. Dust & Dirt. Solenoid box oil level and is there. NOW EASY TO CLEAN RESULT / BENEFIT : EASY TO CLEAN.4 . Hard to Inspect. Hard to Inspect. Oil level marking to be provided for easy inspection. dust falling. No oil level marking in Lubricator. PER WEEK TO 5 MIN. Lack of lubrication Transparent cover to be and inspection. Motor base to clean EXAMPLE OF COUNTERMEASURE AGAINST HARD TO CLEAN SUBJECT : SPLICE PRESS HOSE PIPE HARD TO CLEAN. Machine Dust & Dirt on Solenoid valve station Requirement Solenoid to be covered to prevent Valve & regulators.

EXAMPLE OF VISUAL CONTROL SYSTEMS IMPLEMENTED FOR EASY INSPECTION NOT OK TPM MILL TANK LUBE OIL PRESSURE INDICATOR OK MILL LUBE OIL PRESSURE INDICATOR CHILLED WATER SPRAY INDICATOR MILL LUBRICATION OIL INDICATOR VALVE OPEN/CLOSE INDICATOR 5th TPM National Conference Page 4. CONTAMINATION ELIMINATED. PER DAY SAVING OF Rs.800 PER DAY.5 . PLATFORM PROVIDED TO AVOID TOUCHING OF FABRIC WITH FLOOR. (FABRIC SCRAP 8 Kg. RESULT / BENEFIT : REDUCTION OF QUALITY DEFECT.Birla Tyres JH Step 1-4 EXAMPLE OF COUNTERMEASURE AGAINST SOURCE OF CONTAMINATION SUBJECT : SOURCE OF CONTAMINATION BEFORE AFTER TPM FABRIC TOUCHING THE FLOOR AT BIAS CUTTER DANCER ROLL AND CONTAMINATES WITH DUST.

Making Visual Controls Finalisiation of colour codes to be used for OK.6 . Lubrication. EXAMPLES OF COLOUR CODES. Stands for Inspection Activity. (Daily. Pink Colour for Weekly check sheet. Tightening and Inspection. Making lubrication points on machine. Putting sticker on machine to show inspection points. Close etc. Lubrication. Marking Route near machine Identifying points where visual controls are required. Inspection. Not OK. Tightening.Birla Tyres JH Step 1-4 JISHU HOZEN STEP-3 Finalisiation of Frq. SYMBOLS FINALISED FOR VISUAL CONTROL AND JISHU HOZEN CHECKS TPM Green Colour for “OPEN” symbol. indicating type of lubrication and frq. Preparation of Monitoring Sheet for Record. Open. Making the Points on Machine for Cleaning. Monthly) Group Members meeting to prepare tentative standard for Cleaning. Stands for Lubrication Activity. Stands for Cleaning Activity. TPM Finalisation of format and colour codes. Red Colour for “CLOSE” symbol. Yellow Colour for daily check sheet. 5th TPM National Conference Page 4. Weekly.

Daily Oil upto specified mark. No.Spring Looseness & bolt (Outside) & Missing Main Motor & Blower.) Abnormal Sound.Joints 4 Daily Inspection Ply. Equipment Failure and Quality Defect.Cup. No play and jamming.Spring & bolt (Inside) Looseness & Missing Equipment Failure 2 Daily Inspection Bottom Stitcher Bottom Stitcher Bead Setter Assembly Head Stock Assembly Discs Play.Birla Tyres JH Step 1-4 TPM EXAMPLE OF JISHU HOZEN CHECK RECORDS CRITERIA : INSPECTION: Route Ref.Jamming Gap Air Leakage 05 Secs. Daily Daily Head Stock Drum Collapsing. Operator Equipment Failure and Quality Defect. Equipment Failure 5 Daily Inspection Equipment Failure 5th TPM National Conference Page 4. No air leakage.. Rotary encoder coupling alignment. 1 When Criteria Sub-Assembly Where What How TPM INSPECTION Time / Responsibility.7 . Operator 5 Secs.Cup. Abnormal Sound.) No Oil Leakage Daily Bottom Stitcher Bead Stitcher Bottom Stitcher Disc.) DAILY Route Ref. When SubAssembly Head Stock Where What Method 1 2 3 4 5 6 7 8 1 2 3 4 5 6 Daily Disc Brake Unit (Oil leakage at fittings. No.. Operator 15 Secs. Pipes. Lubricator oil Level. Operator Remarks Daily Inspection Bead Setter Assembly Ply. 5 Secs. Daily Bead Stitcher Tail Stock Bead tool air fittings ( Inside ). No Mis-alignment. Operator 05 Secs. 3 Daily Inspection Air Cylinder. (Signature) JISHU HOZEN CHECK LIST (59J TYRE BUILDING M/C.

Step . Jishu Hozen Step-4 (GENERAL INSPECTION) Advance Can check machine by practicing Jishu Hozen.1. Lubrication. Tightening and Inspection. Jishu Hozen Step .Birla Tyres JH Step 1-4 PROCESS OF TRAINING TPM Objective and Curriculum for Operators Skill Assessment Preparation of Training Material and Facilities Training Implementation Evaluation Recording Standard Basic Objective Can set. Training Topic Correct operation (Work instruction. Specification and Safety). Category 5th TPM National Conference Page 4.8 . adjust. run the machine correctly. Know Machine components and maintain them by practicing Jishu Hozen. 2 & 3 (Practice of Cleaning.I.4 : GENERAL INSPECTION TPM Establishment of General Inspection Category Preparation of Training Material Training Calender Group Leader Training Members Training General Inspection Practice Inspection Skill Assessment Revision of Check Sheet Audit Next G.

I. Tyre Bldg. 4 Roll & Dip Extruders Bias Cutting & Band Building Bead Room Truck Tyre Bldg. 6 4 12 15 8 12 10 12 14 23 13 6 ➨Examples of TRAINING MATERIAL ON JH 4TH STEP GENERAL INSPECTION AREA :. LEAD SCREW AND FEED NUT LEAD SCREW LUBRICATION LEAD SCREW & FEED NUT PLAY. ITEMS PERSONS INVOLVED: Training Department. Pass. (90 DEG. SPROCKET ALIGNMENT SPROCKET KEY / KEYWAY / DAMAGE / WORN OUT. ITEMS DAMAGED / WORN OUT KEY / KEY WAY DAMAGED GEAR TEETH GEAR OIL LEAKAGE TPM MOTOR SHAFT TRANSMISSION SYSTEM BEAD TOOL TRAVERSE MOVEMENT SPEED REDUCER CHAIN & SPROCKET ELECTRICAL CONTROL SYSTEM LUBRICATION OF CHAIN LOOSENESS / TIGHTNESS OF CHAIN.I.4 : GENERAL INSPECTION ESTABLISHMENT OF GENERAL INSPECTION CATEGORIES : Area Categories Nuts & Bolts Lubrication Transmission Pneumatics Electrical Hydraulics Banbury 3 Roll. BEAD TOOL ANGLE.TRUCK TYRE BUILDING EQUIPMENT:.Birla Tyres JH Step 1-4 Step . Tyre Curing Tube Section TPM X Training Material X X X X X X PREPARATION OF TRAINING MATERIAL (CATEGORY WISE) : OPLS Categories Nuts & Bolts Lubrication Transmission Pneumatics Electrical Hydraulic MODLES / CUT SECTIONS MODLES FOR G.I. Maintenance Incharge.M. TYRE BUILDING MACHINE TRANSMISSION SYSTEM CATEGORY :(BEAD TOOL TRAVERSE MOVEMENT) MECHANISM G. Production Incharge.9 .) BEAD TOOL 5th TPM National Conference Page 4. PARTS G.I.H.

QUALITY DEFECT WILL BE GENERATED FEED NUT LIFE WILL BE REDUCED MAINTENANCE COST WILL INCREASE.H.. WHY TO CHECK LEAD SCREW NOT LUBRICATED LEAD SCREW AND FEED NUT WILL WEAR OUT. PART:MACHINE :LEAD SCREW AND FEEDM.10 .H. ➨Examples of TRAINING MATERIAL ON JH 4TH STEP G. ITEM :TRANSMISSION LUBRICATION OF LEAD SCREW.M.TRUCK TYRE BUILDING EQUIPMENT:. IF LEAD SCREW IS DRY.B. TYRE BUILDING MACHINE CATEGORY :TRANSMISSION SYSTEM (BEAD TOOL TRAVERSE MOVEMENT) TPM MOTOR SHAFT SPEED REDUCER CHAIN & SPROCKET LEAD SCREW AND FEED NUT BEAD TOOL LEAD SCREW LUBRICATION LEAD SCREW & FEED NUT PLAY.I. BEAD TOOL WILL NOT REACH AT REQUIRED POSITION.M. PLAY WILL DEVELOP. LUBRICATE THE LEAD SCREW BY APPLYING GREASE. TPM CHECKING METHOD WHAT TO DO VISUALLY CHECK THAT LEAD SCREW IS NOT DRY OF LUBRICATION.I. T.Birla Tyres JH Step 1-4 ➨Examples of TRAINING MATERIAL ON JH 4TH STEP GENERAL INSPECTION AREA :.I. NUT CATEGORY :G.I. 5th TPM National Conference Page 4.

SKILL Each question carries one mark.TOPIC . 4 . .4) S. Can you Identify The Pneumatic 1 Equipment . T6 T3 T . BASIC (REQUIRED LEVEL . NO. 1 3. What are the check point of FRL Unit. .Birla Tyres JH Step 1-4 INSPECTION SKILL ASSESSMENT INSPECTION SKILL ASSESSMENT :TOPIC:. CARD NUMBER 2546 2533 K S K S 1 1 1 1 1 1 1 1 1 1 TPM S 1 1 1 1 1 5 2528 K S 1 1 1 1 1 1 1 1 2516 K S 1 1 1 1 1 1 5 1 1 1 1 5 2517 K S 1 1 1 1 1 1 5 1 1 1 1 4 1 1 5 1 1 4 1 4 4 4 4 INDIVIDUAL RECORD OF SKILL LEVEL T1 (SPIDER DIAGRAM) T2 1 .11 . . . What are the failures related to Pneumatic Cylinders in your area 4.80% SCORE OF KNOWLEDGE 3. -KNOWLEDGE SATISFACTORY. Question 2606 K 1. 2.Knowledge and Maintenance of Pneumatic System. Score 4 K .80% SCORE OF BOTH KNOWLEDGE AND SKILL. How to Identify out of calibration 1 Pneumatic Equipment.KNOWLEDGE S . What is a Celebration tag.EACH CO-CENTRIC CIRCLE LEVEL 0 TO 4.SKILL SATISFACTORY. T5 T4 EFFECT OF STEP-4 TRAINING NUMBER OF JH KAIZENS SUGGESTED BY OPERATOR = 133 TO STOP SPILLAGE LEAKAGE (OIL / POWDER) 96 FOR EASY WORKING 105 QUALITY WASTE CONTROL 45 13 TPM SAFETY OTHERS 48 26 FREQUENCY PER MONTH 300 250 200 150 100 50 0 296 EQUIPMENT FAILURE DUE TO NO / POOR INSPECTION CASES PER MONTH 25 20 15 10 5 0 QUALITY DEFECT DUE TO NO / POOR INSPECTION 24 18 122 44 0 STEP# 2 STEP# 3 STEP# 4 8 0 STEP# 2 STEP# 3 STEP# 4 STEP# 1 STEP# 1 5th TPM National Conference Page 4. 2.80% SCORE OF SKILL.KNOWLEDGE AND SKILL BOTH UNSATISFACTORY. 1 5.KNOWLEDGE AND SKILL BOTH SATISFACTORY .YEAR WISE LEVEL INDICATED BY DIFFERENT COLOURED LINES.

12 .Birla Tyres JH Step 1-4 TPM 5th TPM National Conference Page 4.