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Mr.

Deepak Sahoo Consultant

To PREVENT EQUIPMENT DETERIORATION TO MAINTAIN EQUIPMENT IN OPTIMAL CONDTION TO ESTABLISH BASIC EQUIPMENT CONDITION TO ELIMINATE EQUIPMENT FAILURE TO MAKE OPERATOR EQUIPMENT COMPETENT TO ELIMINATE Quality Defects TO ELIMINATE COST LOSSES
Mr. Deepak Sahoo Consultant

EQUIPMENT DETERIORATION Natural Deterioration Accelerated Deterioration


Extend Life Time Eliminate Causes

Corrective Maintenance Prevent errors by improving operability Improve Maintainability & Repair Quality Improve safety & Reliability

Establish Basic Condition Cleaning : Eliminate all dust & Dirt Lubricating : Keep lubricants clean and replenished Tightening : Keep nuts & bolts secure
Mr. Deepak Sahoo Consultant

Mr. Deepak Sahoo Consultant

PREVENTIVE MEDICINE FOR EQUIPMENT = PREVENTIVE MAINTENANCE


Preventive Medicine

Daily Prevention

Health checkup (Diagnosis)


Measures deterioration
Inspection (Diagnosis)

Early treatment

Prevents deterioration
Daily maintenance (lubricate, clean, adjust, inspect

Repair deterioration
Make preventive repairs (advance replacement)

Preventive Maintenance

Mr. Deepak Sahoo Consultant

CLASSIFICATION OF MAINTENANCE ACTIVITIES


Normal operation Preventive maintenance

Maintain preventing & repairing failure Maintenance activities

Daily maintenance Periodical maintenance Predictive maintenance

Breakdown maintenance

Corrective maintenance Improvement of maintainability Improve Prolong equipment life Eliminate maintenance Reduce maintenance hours Improvement of reliability

Maintenance prevention
Design which does not need maintenance

Mr. Deepak Sahoo Consultant

CLASSIFICATION OF DEFECTS
Physical latent defects The defects which are left unattended since they are not physically exposed to naked eyes Psychological latent defects Defects which are left unnoticed due to insufficient knowledge and education of operators or maintenance people

1. Defects which can not be visually observed unless the equipment is dismantled

1. Operator or maintenance mans indifference

2. Defects which can not be visually noticed due to improper installation location of equipment

2. Operator or maintenance man is not well familiarized with types of defects

3. Defects which are likely to be ignored since they are covered with dust or they are heavily soiled

3. Operator or maintenance mans ignorance based on their own judgment


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1.MINOR FLAWS

2. UNFULFILLED BASIC CONDITIONS


3. INACCESSABLE PLACES 4. CONTEMINATION SOURCES 5. QUALITY DEFECT SOURCES 6. UNNECCERY AND NON-URGENT ITEMS 7. UNSAFE PLACES
Mr. Deepak Sahoo Consultant

1.MINOR FLAWS :
Contamination Dust, Dirt, powder, oil, grease, rust, paint Damage Cracking, crushing, deformation, chipping, bending, Play Shaking, falling out, tilting, eccentricity, wear, distortion, corrosion, Slackness Belts, Chains
Abnormal Phenomenon Adhesion Unusual noise, overheating, Vibration, strange smells, discoloration, incorrect pressure or current Blocking, hardening, accumulation of debris, peeling, malfunction
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2. UNFULFILLED BASIC CONDITIONS


Lubrication Lubrication Supply Oil level gauges Tightening Insufficient, Dirty, Unidentified, unsuitable, Leaking Dirty, damaged or deformed lubricant inlets, faulty lubricant pipes Dirty, Damaged, leaking, No indication of correct level Nuts and Bolts slackness, Missing, Crossthreaded, Too long, Crushed, Corroded, Unsuitable washers, wing nuts on backward

Mr. Deepak Sahoo Consultant

3. INACCESSABLE PLACES
Cleaning Checking Machine construction, Covers, Layout, footholds, Space Construction, Covers, Layout, footholds, Instrument position and Orientation, Operating Range display

Lubricating Position of lubricant inlet, construction, height, footholds, lubricant outlets, space Tightening Operation Covers, Construction, Layout size, Space Machine layout, Position of valves, Switches and leavers, Footholds

Adjustment Position of pressure gauges, thermometers, flow meters, moisture gauges, vacuum gauges, etc.
Mr. Deepak Sahoo Consultant

4. CONTEMINATION SOURCES
Product Raw materials Lubricants Gases Leaks, Spills, Spurts, Scattering, Overflow Leaks, Spills, Spurts, Scattering, Overflow Leaking, Spills, Seeping oils, Hydraulic fluids, Fuel oils, etc. Leaking compressed air, gases, steam, vapors, exhaust fumes, etc. Leaking water, Hot, Cold, half finished products, Waste water, Leaking supply lines etc. Flashes, cuttings, packaging materials, and non conforming products. Contaminants by people & Forklifts, Infiltration through cracked walls, broken windows etc.
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Liquids
Scrap Others

5. QUALITY DEFECT SOURCES


Foreign Matter Dust, Rust, powder, chips, moisture, wire scraps, wood pieces, paper pieces, stones etc. Shock Moisture Gain Size Concentration Viscosity Dropping, Jolting, collision, Vibration etc. Too little or Too much, infiltration Abnormalities in screens, Compressed air separators, centrifugal separators, Inadequate warming, heating, compounding, mixing, evaporation, stirring etc. Inadequate warming, heating, compounding, mixing, evaporation, stirring etc.
Mr. Deepak Sahoo Consultant

6. UNNECCERY AND NON-URGENT ITEMS


Machinery Pumps, fans, compressors, columns, tanks etc. Piping equipment Pipes, hoses, ducts, valves, dampers etc. Measuring Temperatures, pressure gauges, vacuum instruments gauges, ammeters etc. Electrical equipment Jigs & Tools Spare parts Wiring, piping, power leads, switches, plugs etc. General tools, cutting tools, jigs, molds, dies, frames etc. Standby equipment, spares, permanent stocks, auxiliary materials, etc.

Makeshift repairs Tape. String, wire, metal plates etc.


Mr. Deepak Sahoo Consultant

7. UNSAFE PLACES
Floors Steps Lights Rotating machinery Lifting Devices Others Unevenness, cracked, holes, projections, peeling, wear of steel chucker plates, slipping. Too steep, irregular, slipping, missing handrails, etc. Dim, out of position, dirty or broken covers, no explosion proofing, etc. Displaced, fallen oil or broken covers, not safe for emergency, missing emergency stop devices Wires, hooks, brakes and other parts of cranes and hoists etc. Special substances, solvents, toxic gases, insulating materials, danger signs, protective clothing etc.
Mr. Deepak Sahoo Consultant

7 Steps of Autonomous Maintenance


Autonomous Management Standardization Autonomous Inspection General Inspection Preparing Tentative Cleaning, Lubrication, Inspection & Retightening Stds. Countermeasures against Sources of contamination & Hard to Access areas

Initial thorough Cleaning

Preparation

Mr. Deepak Sahoo Consultant

Z
E PREPARE A CLEANING & LUBRICATION MAP

R
O S T E

ARRANGE TOOLS
ARRANGE RED & WHITE TAGS HISTROY OF FAILURES TRAINING ON 7 STEPS OF JISHU HOZEN TRAINING ON 7 TYPES OF ABNORMALITIES

Mr. Deepak Sahoo Consultant

CLEANING IS INSPECTION

USE 5 SENSES FOR CLEANING


FIND OUT 7 TYPE OF ABNORMALITIES PUT TAGS ON ABNORMALITIES

PREPARE LIST OF UNFULFILLED BASIC CONDITIONS


Mr. Deepak Sahoo Consultant

White tags for operators

Red Tags to be attended by Maint.

Equipment Name Control No.. Date of detection.

Equipment Name Control No.. Date of detection.

Detected by..
Description of Minor defects .

Detected by..
Description of Minor defects . .. .

..
.

Mr. Deepak Sahoo Consultant

MAKE THE LIST OF HARD TO CLEAN, HARD TO LUBRICATE, HARD TO TIGHTEN, HARD TO INSPECT, HARD TO ADJUST RECORD CLEANING TIME CARRY OUT AUDIT ON 1ST STEP

Areas / Parts

MEETING AFTER THE DAILY ACTIVITIES


REFER TO THE OLD HISTORY RECORDS
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Mr. Deepak Sahoo Consultant

Mr. Deepak Sahoo Consultant

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EXAMPLE OF ABNORMALITY ( LOOSE FITTINGS )

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EXAMPLE OF ABNORMALITY ( LEAKAGES )

Mr. Deepak Sahoo Consultant

RELAY TRAINING

Mr. Deepak Sahoo Consultant

Purpose of Step-2
Eliminate sources of Contamination To improve places where it is difficult to access for cleaning, lubrication, inspection Improved maintainability of Equipment Enable Learning in tackling Equipment Kaizen

Mr. Deepak Sahoo Consultant

STEP 2

COUNTERMEASURES AGAINST SOURCES OF CONTEMINATION AND HARD TO DO

CLITA
COUNTERMEASURES AGAINST SOURCES OF CONTAMINATION MAKE APPROACH EASY FOR CLITA

MAKE EASY TO DO CLITA


SHORTEN CLEANING , LUBRICATING TIME ADOPT CONCEPTS OF LOCALIZED GUARDS RANKING THE PRIORITY PLACES FOR DAILY CLEANING
Mr. Deepak Sahoo Consultant

Finding & Confirmation of Generating Sources


Understand contaminations relationship with Quality, Failures, Maintainability etc. Locate contamination generating sources

Hard to Access Areas


Time consuming Places Places difficult to do.

Analysis of Generating Sources


Understand why do they generate?

Analyzing Hard to Access areas


What type of work is performed? What tools are used? Can work be performed in visible state?
Mr. Deepak Sahoo Consultant

Impact on Equipment Confirm the basic countermeasures

Devising countermeasures to Eliminate Sources of Contamination

Hard to Access Areas


Time consuming Places Places difficult to do.

Eliminate the Source


Eliminate Need to Access Contain (localize) the Contaminant Shield (Protect) the Affected part Improve Cleaning Method

Reduce need to
(Frequency)

Improved Method of C, L, I & R


Less Time & Effort

approach

Improve Accessibility
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Easy to clean

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SOURCE OF CONTAMINATIONS

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Usage of localised guards

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Easy to lubricate

Mr. Deepak Sahoo Consultant

Countermeasures against source of contamination Oil Localisation


Before After

Localised gaurds
The return oil flow from the feed drive gears splash and spread all around the open space inside the machine there by getting contaminated. To avoid the contamination, the return oil flow is channalised from the feed drive gears directly to the lubrication tank
Mr. Deepak Sahoo Consultant

DIFFICULT TO LUBRICATE - EASY TO LUBRICATE

Before
Difficult to Lubricate the oil to gear box

After
Easy to Lubricate the oil to gear box
Mr. Deepak Sahoo Consultant

Easy to Inspect

Mr. Deepak Sahoo Consultant

THEME:
To reduce Inspection time

LOSS NO. 8A

KAIZEN
LOSS STRUCTURE: Inspection Time Reduction IDEA: To bring the pressure gauge for K.O. system outside the machine for easy inspection COUNTERMEASURE: Before After

MACHINE:

10B3S KAIZEN START 10.05.2001 KAIZEN FINISH 25.05.2001

TEAM: J. Sriram Karunairaja Franklin Sivakumar Ramalingam BENEFITS :

BENCH MARK TARGET PROBLEM:

30 sec / Day 2 sec / Day

Time saving = 28 sec / Day

Inspection is very difficult and taking more time in the pressure gauge for K.O. system

Man hours saved per year = 15 hours

Pressure gauge Inside the M/c

Pressure gauge Outside the M/c Easy to Inspect

Other Benefits Inspection becomes easy

Difficult to Inspect
ANALYSIS:
WHY 1 Problem : Inspection is difficult WHY 2 Pressure gauge kept inside the machine
15

RESULT:
Sec. 30 sec / change
30

HORIZONTAL DEPLOYMENT :

WHY 3 By machine design

Inspection is very difficult and it is taking moretime in pressure gauge for K.O. system

Better

No of Areas Identified
2 sec / Day
0

: 5 Nos.

Implemented : 5 Nos.

Before

After

Mr. Deepak Sahoo Consultant

Mr. Deepak Sahoo Consultant

DIFFICULT TO INSPECT- EASY TO INSPECT


Before After

Difficult to Inspect the belt condition

Easy to Inspect the belt condition


Mr. Deepak Sahoo Consultant

Purpose of Step-3
Continuously Maintaining and Management of Basic equipment conditions, (I.e. Cleaning, Lubrication, Retightening) Enhancing Equipment Reliability & Maintainability Preparing standards that can be followed easily Ideas for Visual Improvement

Mr. Deepak Sahoo Consultant

Cleaning, Inspection, Lubrication & Retightening


Clarification of places & location by all Deciding tools, jigs to be used

Decided the method


Decide Standard / Level Identify Problems & decide Trouble Shooting Clarify Period Set Goal Time Use of Visual Control Visual ways to allow correct decision in short span of time on the spot by only seeing

Prepare Standards & Calendar (Schedule)


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C, L, I, R Standards Implementing Cleaning, Lubrication, Inspection, & Retightening

Difference with Goal Time


Kaizen (Implement & Confirm)

Feedback

Audit Passed

Mr. Deepak Sahoo Consultant

STEP 3
STANDARDS FOR CLEANING, LUBRICATING AND TIGHTENING STANDARDS ARE MADE BY OPERATORS THEMSELVES WITH GUIDENCE BY PM

STANDARDS ARE MADE BY USING 5W 1H


STANDARDS SHOULD BE EASILY UNDERSTOOD BY EVERY ONE INTRODUCE EXTENSIVE VISUAL CONTROLS
Mr. Deepak Sahoo Consultant

CLEANING LUBRICATION & INSPECTION STANDARDS

Cleaning activities :

Lubrication activities :

Inspection activities :

Sl. Route No. Reference

Criteria

Sub Assembly

Where

What

How

Responsibility Time (Who)

Remarks (Impact of overlooking)

Cleaning

Dual Ext. steel belt

Steel belt

Dust & dirt

20 Sec

Operator

Quality defect

Lubrication

Dual Ext. skiver

Driven roll EP-2 grease bearing

30 Sec

Operator

Equipment failure

Inspection Head stock

Inside pull No damage out ring

5 Sec

Operator

UNSAFE

Mr. Deepak Sahoo Consultant

VISUAL CONTROLS
Activity

Symbol

Tools

CLEAN

LUB

INSPECTION

I S NOC
Mr. Deepak Sahoo Consultant

Indication marks for nuts & bolts

Indication for valve controls

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Fan to indicate the function of Chiller Unit

Arrow sign for indicating the rotating direction of Motor


Mr. Deepak Sahoo Consultant

Mr. Deepak Sahoo Consultant

Mr. Deepak Sahoo Consultant

Mr. Deepak Sahoo Consultant

Mr. Deepak Sahoo Consultant

Avoid such extremes with some over enthusiastic teams

Mr. Deepak Sahoo Consultant

Purpose of Step-4
Bringing up equipment consciousness in the process of measuring & restoring deterioration. To understand structures, functions & principles of equipment & learn their optimal conditions to thoroughly check principal mechanisms & parts of the equipment

Mr. Deepak Sahoo Consultant

Preparation for Education & Training


Identifying general Inspection Items Basic Items:
Machine Elements
Hydraulic System Electrical systems

Lubrication system
Pneumatic System Equipment Safety

Bolts & Nuts


Driving Systems Process Conditions

Additional Items: Specific to the Equipment Preparation of text for General Inspection Education & Training Schedule Planning for General Inspection Education & Training
Mr. Deepak Sahoo Consultant

Implementation of General Inspection Education & Training


Implementation of Education for Circle Leaders Preparation of education transmission to Circle Members
Implementation of education transmission to Circle Members

Implementation of General Inspection


Implementation of General Inspection
Preparation of Abnormalities List for Circle Meetings Discussion & Planning Countermeasures Restoration of Abnormalities List

Mr. Deepak Sahoo Consultant

Prevention of Irregularities in General Inspection Items


Preparation of Temporary Criteria for Daily Inspection

Inspection skill Check Autonomous Audit & Application for receiving diagnosis
Implementation of Audit Solutions to the Items Pointed out

Mr. Deepak Sahoo Consultant

Prevention of Irregularities in General Inspection Items


Preparation of Temporary Criteria for Daily Inspection

Inspection skill Check Autonomous Audit & Application for receiving diagnosis
Implementation of Audit Solutions to the Items Pointed out

Mr. Deepak Sahoo Consultant

Initial Clean-up ( Cleaning is Inspection) ( Cleaning with meaning) (Doing with purpose)
Taking countermeasure for forced deterioration and improving hard to access area Preparing tentative standards for cleaning and lubrication

Mr. Deepak Sahoo Consultant

Four Steps to Become An Operator Strong on Equipment And Autonomous Maintenance


Autonomous Maintenance 7 steps Four steps to become an operator strong on equipment

7 All-out autonomous management 4 Master how to repair the equipment

6 Orderliness and tidiness 3 5 Autonomous check-up 4 General inspection 2

Learn how to operate the equipment with the required accuracy and how to evaluate the product quality Study the mechanism and functions of equipment and machines Familiarize with the concept of equipment maintenance and improvement and with how to put the idea into practical realization

3 Formulation of clean-up and lubrication standards


2 Measures against sources of outbreaks

1
1 Initial clean-up

Mr. Deepak Sahoo Consultant