2. BACKGROUND SCENEBACKGROUND SCENE
(MACHINE BUILDING DIVISION)(MACHINE BUILDING DIVISION)
Poor
Equipment
Condition
Blame
syndrome for
breakdowns
“I operate
you Maintain”
mentality
Dirty
Machine
Oil leakage
Dirty/oily floor
Scattered chipsLong
Searching time
for tools/ tackles
Inadequate
operator knowledge
about equipment

4. JISHU HOZEN STEP 1: INITIAL CLEANINGJISHU HOZEN STEP 1: INITIAL CLEANING
Identifying abnormalities through stratified fuguai tags:
Interesting findings not known so far
Changing Look of the machines: providing sense of
pride to the workmen
Increased awareness to identify: difficult to
clean/lubricate/ inspect areas and the need for counter
measures
Specific tools developed in-house for cleaning difficult-
to-access areas
Spectrum covered small capacity welding machines to
as big as 100 Ton – capacity machines, where each job
goes on for months (to a size of 8.5 mφ components)

5. BEFOREBEFORE AFTERAFTER
FEEL GOOD CORNERFEEL GOOD CORNER

6. RESULTS OF STEP 1RESULTS OF STEP 1
More than 14000 fuguai tags identified and
attended
In a span of about couple of years, 114 machines
were adopted for JH out of 147 machines
Concept of doing JH in non-machine areas
introduced e.g. in fabrication/ assembly areas, sub-
stores.

7. TAG CLASSIFICATIONTAG CLASSIFICATION
BLUEBLUE & WHITE& WHITE : For Mechanical
GREENGREEN & WHITE& WHITE : For Electrical
BLACK & WHITEBLACK & WHITE : For Operator
Fuguai Age Analysis & Focus

8. NOS.NOS.
PERIODPERIOD
FUGUAI TAG STATISTICSFUGUAI TAG STATISTICS

9. JISHU HOZEN STEP 2 ACTIVITIESJISHU HOZEN STEP 2 ACTIVITIES
 Countermeasures adopted for major problems
responsible for making machines dirty
flying chips
oil leakage
oil coolant splashing
bird droppings and others
dirt/dust/slime
 Innovative kaizens by workmen/supervisors

10. PROBLEMSPROBLEMS
BEFOREBEFORE
AFTERAFTER
COUNTERMEASURESCOUNTERMEASURES

11. RESULTS OF STEP 2RESULTS OF STEP 2
 JH Kaizen done (Nos.) : 1227
 One Point Lessons conducted (Nos.) : 699
 Breakdown status (due to poor JH) [Hrs.) Reduction from 680 to 100
 Oil consumption reduction (ltrs/month) From 1042 to 425
 Noise level reduction (db) : From 125 to 80
 Cleaning time reduction (average) From 60 to 10
[min/shift/machine]
 Indirectly saving maintenance time (Hrs.) From 965 to 220

12. NOS.NOS.
PERIODPERIOD
JH OPL STATISTICSJH OPL STATISTICS

13. JISHU HOZEN STEP 3JISHU HOZEN STEP 3
 Standardization for : CLIT
Colour codes and symbols
Lubrication and inspection check sheets
Greasing points marking
Markings on belts / pressure gauges
Oil level indicators
I-marking
Stickers for hands/eyes/arrows
Station concept with clockwise numbering
system
 Cleaning time: Benchmark/ target/ achieving the minimum time and its
standardization
 Surrounding area upliftment

14. CLEANING TIME REDUCTIONCLEANING TIME REDUCTION
Time inTime in
Mins/Shift/Mins/Shift/
MachineMachine
PERIODPERIOD

15. STEP VII
STEP VI
STEP V
STEP IV
STEP III
STEP II
STEP I
STEPWISE STATISTICS OF MACHINES IN JISHU HOZEN
(114 Machines)
04
23
05
77
05
0
0

16. TYPICAL NOVEL TECHNIQUESTYPICAL NOVEL TECHNIQUES
Red stickers on machine body for oil leakage (vigorous “dry“dry
floor”floor” campaign)
Pick up rounds by Managers
Metamorphosis amongst people (managers/staff/workmen)
through communications/ visits/contests/recognition
Displays/ slogans/ posters/ banners/ leaflets
Area of concern: Maintenance Dept. interaction with JH for skill
improvement Wanting