AUTONOMOUS MAINTENANCE ( JISHU HOZEN )

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2. (AUTONOMOUS MAINTENANCE)
•Individual preserving one’s own equipment
•Significant change from early theory of
“I Manufacture – You Repair” or “ I Make – You Fix”
•Theme is
“ If equipment changes – people will change
If people change – shop will change.”
•Operation and Maintenance are like wheels on both sides of
a car.
•I can decide, I can do, I am empowered to do.
JISHU – HOZEN
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4. A.M. ELIMINATES THE BITTER
COMPLAINTS WHICH COME FROM …….
“PRODUCTION” “MAINTENANCE”
•Maintenance does not
know its job
•They take too long to fix
the equipment
•This equipment is so
antiquated, no wonder it
breaks down
•We are too busy to do
vital daily checks.
•They (Production) don’t
know how to operate
•We get lot of repairs so
we don’t have ample to do
a real corrective action
and are forced to only do
disposition
•We repair the standards,
but they don’t do the
checks
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5. A. Activities to prevent deterioration
By correct operation, Improvement of basic conditions and
adjustments to prevent quality defects.
B. Activities to measure deterioration
By senses (touch, see, hear, smell)
By vibration, fluid analysis etc.
C. Activities to rectify deterioration
By improving reliability, maintainability of machines (MTBF, MTTR)
ROLE OF PRODUCTION ROLE OF MAINTENANCE
•Play vital role in A. Also
records maintenance data for
prevention of recurrences of
problem and MP design
•Play role in B by five senses
•Play role in C by prompt
reporting and assisting in
sporadic failure
•Play role in A as guide and educationist and
providing help in identifying areas “ sources of
problem” and “ hard to Clean”.
•Play role in B by vibration, fluid Analysis
•Play major role in C by improving MTBF,
MTTR
•Besides that they maintain MIS, work for new
equipment design and set up maintenance
standards
CLASSIFICATION OF MAINTENANCE ACTIVITIES
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6. 0. PREPARATION STAGE ( 1 ‘S’, 2 ‘S’ & TRAINING )
1. INITIAL CLEANING & INSPECTION
2. COUNTER MEASURE AGAINST SOURCE OF
CONTAMINATION AND HARD TO ACCESS AREA
3. CREATION OF TENTATIVE STANDARDS
4. GENERAL INSPECTION & SKILL DEVELOPMENT
5. AUTONOMOUS INSPECTION
6. STANDARDISATION
7. CONSISTENT AUTONOMOUS MANAGEMENT
SEVEN STEPS OF JISHU HOZEN
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7. STEP 1
CLEAN & INSPECT

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9. ELIMINATE PROBLEM SOURCE
AND HARD TO ACCESS AREA
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STEP 2

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12. Modify Equipment to make Cleaning Easier
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14. ESTABLISHING TENTATIVE
STANDARDS FOR JISHU-HOZEN
( CLEANING & LUBRICATION)
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STEP 3

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16. Model Equipment Selection Standards
Category No. Item Evalua
tion
Score
Evaluation guide
Productio
n aspect
(PD)
1 Average level of operation 4 2 1 80% or greater: 4
60% or less: 1
2 Presence of a spare or
alternative machine, and
the ease of switching over
to that machine
4 2 1 None, or requires a larges amount
of time to switch over: 4
Present, & easy to switch over: 1
3 Effect that a failure has on
other equipment
4 2 1 Effects a large amount of
equipment inside the plant: 4
Has nearly no effect on other
equipment:1
4 Failure frequency (MTBF) 4 2 1 4 times a month or greater:4 1
time per day or less:1
5 Downtime for repairing
failure (MTTR)
4 2 1 Avg. of one time/day or greater : 4
Avg. of one time/Hr. or fewer : 1
Quality (Q) 6 Effect on product quality
assurance
4 2 1 Large effect : 4
Almost No effect : 1
7 Amount lost from average
drop in quality per failure
incident
4 2 1 Rs. 25,000/- or greater : 4
Rs. 2,500/- or greater : 1
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17. Model Equipment Selection Standards – Contd.
Category No. Item Evalua
tion
Score
Evaluation guide
Cost ( C ) 8 Amount lost in energy,
material and labour
expenses due to failure
4 2 1 Rs. 25,000/- or greater : 4
Rs. 2,500/- or greater : 1
9 Extent of overall repair
cost
4 2 1 Monthly avg. of Rs. 25,000/ or
greater : 4
Monthly avg. of Rs. 2,500/ or
less : 4
Safety ( S
)
10 Risk that failure will cause
injury or illness
4 2 1 Quite large risk : 4
Virtually no risk : 1
11 Risk that failure will cause
pollution
4 2 1 Quite large risk : 4
Virtually no risk : 1
General Evaluation Grade : A B C
Use the points in the score column for evaluation, and use no other pints
General evaluation standard 26 points or greater : Rank A (greater than 60% of
maximum)
18 points or greater : Rank B (40-60% of maximum)
17 points or less : Rank C (Under 40% of maximum)
The model machine selected should be an “A” rank machine, and should have a
sufficient level of explicability in other machines. Imp_cellMHL