Jishu Hozen or Autonomous Maintenance

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Jishu Hozen or Autonomous Maintenance

  1. 1. Mr. Deepak Sahoo Consultant
  2. 2. •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
  3. 3. EQUIPMENT DETERIORATIONNatural Deterioration Accelerated Deterioration Extend Life Time Eliminate CausesCorrective Maintenance Establish Basic Condition• Prevent errors by • Cleaning : Eliminate improving operability all dust & Dirt•Improve Maintainability • Lubricating : Keep & Repair Quality lubricants clean and• Improve safety replenished & Reliability • Tightening : Keep nuts & bolts secure Mr. Deepak Sahoo Consultant
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  5. 5. PREVENTIVE MEDICINE FOR EQUIPMENT = PREVENTIVE MAINTENANCE Preventive Medicine Health Daily Early checkup Prevention treatment (Diagnosis)Prevents Measures Repairdeterioration deterioration deterioration Daily maintenance Make preventive Inspection (lubricate, clean, repairs (advance (Diagnosis) adjust, inspect replacement) Preventive Maintenance Mr. Deepak Sahoo Consultant
  6. 6. CLASSIFICATION OF MAINTENANCE ACTIVITIES Normal operation Daily maintenance Maintain Preventive maintenance Periodical maintenance preventing & Predictive maintenance repairing failure Breakdown maintenanceMaintenanceactivities Corrective maintenance Improvement of maintainability Improvement of reliability Improve Prolong equipment life Eliminate maintenance Maintenance prevention Reduce maintenance hours Design which does not need maintenance Mr. Deepak Sahoo Consultant
  7. 7. CLASSIFICATION OF DEFECTS Physical latent defects Psychological latent defectsThe defects which are left unattended Defects which are left unnoticed due tosince they are not physically exposed to insufficient knowledge and education ofnaked eyes operators or maintenance people1. Defects which can not be visually 1. Operator or maintenance man’sobserved unless the equipment is indifferencedismantled2. Defects which can not be visually 2. Operator or maintenance man is not wellnoticed due to improper installation familiarized with types of defectslocation of equipment3. Defects which are likely to be ignored 3. Operator or maintenance man’s ignorancesince they are covered with dust or they based on their own judgmentare heavily soiled Mr. Deepak Sahoo Consultant
  8. 8. 1.MINOR FLAWS2. UNFULFILLED BASIC CONDITIONS3. INACCESSABLE PLACES4. CONTEMINATION SOURCES5. QUALITY DEFECT SOURCES6. UNNECCERY AND NON-URGENT ITEMS7. UNSAFE PLACES Mr. Deepak Sahoo Consultant
  9. 9. 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 Unusual noise, overheating, Vibration, strange Phenomenon smells, discoloration, incorrect pressure or current Adhesion Blocking, hardening, accumulation of debris, peeling, malfunction Mr. Deepak Sahoo Consultant
  10. 10. 2. UNFULFILLED BASIC CONDITIONSLubrication Insufficient, Dirty, Unidentified, unsuitable, LeakingLubrication Dirty, damaged or deformed lubricant inlets,Supply faulty lubricant pipesOil level gauges Dirty, Damaged, leaking, No indication of correct levelTightening Nuts and Bolts slackness, Missing, Cross- threaded, Too long, Crushed, Corroded, Unsuitable washers, wing nuts on backward Mr. Deepak Sahoo Consultant
  11. 11. 3. INACCESSABLE PLACESCleaning Machine construction, Covers, Layout, footholds, SpaceChecking Construction, Covers, Layout, footholds, Instrument position and Orientation, Operating – Range displayLubricating Position of lubricant inlet, construction, height, footholds, lubricant outlets, spaceTightening Covers, Construction, Layout size, SpaceOperation Machine layout, Position of valves, Switches and leavers, FootholdsAdjustment Position of pressure gauges, thermometers, flow meters, moisture gauges, vacuum gauges, etc. Mr. Deepak Sahoo Consultant
  12. 12. 4. CONTEMINATION SOURCESProduct Leaks, Spills, Spurts, Scattering, OverflowRaw materials Leaks, Spills, Spurts, Scattering, OverflowLubricants Leaking, Spills, Seeping oils, Hydraulic fluids, Fuel oils, etc.Gases Leaking compressed air, gases, steam, vapors, exhaust fumes, etc.Liquids Leaking water, Hot, Cold, half finished products, Waste water, Leaking supply lines etc.Scrap Flashes, cuttings, packaging materials, and non conforming products.Others Contaminants by people & Forklifts, Infiltration through cracked walls, broken windows etc. Mr. Deepak Sahoo Consultant
  13. 13. 5. QUALITY DEFECT SOURCESForeign Matter Dust, Rust, powder, chips, moisture, wire scraps, wood pieces, paper pieces, stones etc.Shock Dropping, Jolting, collision, Vibration etc.Moisture Too little or Too much, infiltrationGain Size Abnormalities in screens, Compressed air separators, centrifugal separators,Concentration Inadequate warming, heating, compounding, mixing, evaporation, stirring etc.Viscosity Inadequate warming, heating, compounding, mixing, evaporation, stirring etc. Mr. Deepak Sahoo Consultant
  14. 14. 6. UNNECCERY AND NON-URGENT ITEMSMachinery Pumps, fans, compressors, columns, tanks etc.Piping equipment Pipes, hoses, ducts, valves, dampers etc.Measuring Temperatures, pressure gauges, vacuuminstruments gauges, ammeters etc.Electrical Wiring, piping, power leads, switches, plugsequipment etc.Jigs & Tools General tools, cutting tools, jigs, molds, dies, frames etc.Spare parts Standby equipment, spares, permanent stocks, auxiliary materials, etc.Makeshift repairs Tape. String, wire, metal plates etc. Mr. Deepak Sahoo Consultant
  15. 15. 7. UNSAFE PLACESFloors Unevenness, cracked, holes, projections, peeling, wear of steel chucker plates, slipping.Steps Too steep, irregular, slipping, missing handrails, etc.Lights Dim, out of position, dirty or broken covers, no explosion proofing, etc.Rotating Displaced, fallen oil or broken covers, not safe formachinery emergency, missing emergency stop devicesLifting Wires, hooks, brakes and other parts of cranes andDevices hoists etc.Others Special substances, solvents, toxic gases, insulating materials, danger signs, protective clothing etc. Mr. Deepak Sahoo Consultant
  16. 16. 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 areasInitial thorough Cleaning Preparation Mr. Deepak Sahoo Consultant
  17. 17. ZE • PREPARE A CLEANING & LUBRICATION MAPR • ARRANGE TOOLSO • ARRANGE RED & WHITE TAGSS • HISTROY OF FAILUREST • TRAINING ON 7 STEPS OF JISHU HOZENE • TRAINING ON 7 TYPES OF ABNORMALITIESP Mr. Deepak Sahoo Consultant
  18. 18. • 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
  19. 19. White tags for operators Red Tags to be attended by Maint. Equipment Name ……………… Equipment Name ……………… Control No…………………….. Control No…………………….. Date of detection………………. Date of detection………………. Detected by…………………….. Detected by…………………….. Description of Minor defects Description of Minor defects …………………………………. …………………………………. ………………………………….. ………………………………….. …………………………………. …………………………………. Mr. Deepak Sahoo Consultant
  20. 20. • MAKE THE LIST OF• HARD TO CLEAN,• HARD TO LUBRICATE,• HARD TO TIGHTEN, Areas / Parts• HARD TO INSPECT,• HARD TO ADJUST•RECORD CLEANING TIME• CARRY OUT AUDIT ON 1ST STEP• MEETING AFTER THE DAILY ACTIVITIES• REFER TO THE OLD HISTORY RECORDS Mr. Deepak Sahoo Consultant
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  24. 24. EXAMPLE OF ABNORMALITY ( LOOSE FITTINGS ) Mr. Deepak Sahoo Consultant
  25. 25. EXAMPLE OF ABNORMALITY ( LEAKAGES ) Mr. Deepak Sahoo Consultant
  26. 26. RELAYTRAININGMr. Deepak Sahoo Consultant
  27. 27. Purpose of Step-2Eliminate sources of ContaminationTo improve places where it is difficult to access for cleaning, lubrication,inspectionImproved maintainability of EquipmentEnable Learning in tackling Equipment Kaizen Mr. Deepak Sahoo Consultant
  28. 28. COUNTERMEASURES AGAINST SOURCESSTEP 2 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
  29. 29. Finding & Confirmation Hard to Access Areas of Generating Sources•Understand contaminations relationship •Time consuming Placeswith Quality, Failures, Maintainability •Places difficult to do.etc.•Locate contamination generating sources Analysis of Analyzing Generating Sources Hard to Access areas•Understand why do they generate? • What type of work is performed?•Impact on Equipment • What tools are used?•Confirm the basic countermeasures • Can work be performed in visible state? Mr. Deepak Sahoo Consultant
  30. 30. Devising countermeasures Hard to Access Areas to EliminateSources of Contamination Time consuming Places •Places difficult to do. Eliminate the Source Eliminate Need to Access Contain (localize) the Contaminant Reduce Improved need to Method of Shield (Protect) the (Frequency) C, L, I & R Affected part approach Less Time & Effort Improve Improve Accessibility Cleaning Method Mr. Deepak Sahoo Consultant
  31. 31. Easy to clean Mr. Deepak Sahoo Consultant
  32. 32. SOURCE OF CONTAMINATIONS Mr. Deepak Sahoo Consultant
  33. 33. Usage of localised guards Mr. Deepak Sahoo Consultant
  34. 34. Easy to lubricate Mr. Deepak Sahoo Consultant
  35. 35. Countermeasures against source of contamination Oil LocalisationBefore After Localised gaurdsThe return oil flow from the feed drive gears splash and spread all around theopen space inside the machine there by getting contaminated. To avoid thecontamination, the return oil flow is channalised from the feed drive gearsdirectly to the lubrication tank Mr. Deepak Sahoo Consultant
  36. 36. DIFFICULT TO LUBRICATE - EASY TO LUBRICATEBefore After Difficult to Lubricate the oil to Easy to Lubricate the oil to gear box gear box Mr. Deepak Sahoo Consultant
  37. 37. Easy to Inspect Mr. Deepak Sahoo Consultant
  38. 38. THEME: LOSS NO. KAIZEN MACHINE: 10B3S KAIZEN START LOSS STRUCTURE: TEAM: J. SriramTo reduce Inspection time 8A Inspection Time Reduction Karunairaja 10.05.2001 Franklin KAIZEN FINISHBENCH MARK 30 sec / Day IDEA: To bring the pressure gauge for K.O. system outside the Sivakumar 25.05.2001TARGET 2 sec / Day machine for easy inspection RamalingamPROBLEM: COUNTERMEASURE: BENEFITS : Before After Time saving = 28 sec / Day Man hours saved per year = 15 hours Inspection is very difficult and taking more time in the pressure Pressure Other Benefits gauge for K.O. system Pressure gauge Inspection becomes easy gauge Inside the M/c Outside the M/c Difficult to Easy to Inspect InspectANALYSIS: Problem : Inspection is difficult RESULT: HORIZONTAL DEPLOYMENT :WHY 1 WHY 2 WHY 3 Sec. By machine 30 sec / change Pressure gauge 30Inspection is Better kept inside the designvery difficult No of Areasand it is machinetaking 15 Identified : 5 Nos.moretime inpressure Implemented : 5 Nos. 2 sec / Daygauge for 0K.O. system Before After Mr. Deepak Sahoo Consultant
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  40. 40. DIFFICULT TO INSPECT- EASY TO INSPECT Before AfterDifficult to Inspect the belt Easy to Inspect the belt condition condition Mr. Deepak Sahoo Consultant
  41. 41. Purpose of Step-3Continuously Maintaining and Management of Basic equipment conditions,(I.e. Cleaning, Lubrication, Retightening)Enhancing Equipment Reliability & MaintainabilityPreparing standards that can be followed easilyIdeas for Visual Improvement Mr. Deepak Sahoo Consultant
  42. 42. Cleaning, Inspection, Lubrication & RetighteningClarification of places & location by allDeciding tools, jigs to be usedDecided the methodDecide Standard / LevelIdentify Problems & decide Trouble ShootingClarify PeriodSet Goal Time Use of Visual ControlVisual ways to allow correctdecision in short span of time on Prepare Standards &the spot by only seeing Calendar (Schedule) Mr. Deepak Sahoo Consultant
  43. 43. C, L, I, R Standards Implementing Cleaning, Lubrication, Inspection, & Retightening Difference with Goal Time Kaizen (Implement & Confirm)Feedback Audit Passed Mr. Deepak Sahoo Consultant
  44. 44. 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
  45. 45. CLEANING LUBRICATION & INSPECTION STANDARDS Cleaning activities : Lubrication activities : Inspection activities : RemarksSl. Route Sub - Responsibility Criteria Where What How Time (Impact ofNo. Reference Assembly (Who) overlooking) Dual Ext. 1 Cleaning Steel belt Dust & dirt 20 Sec Operator Quality defect steel belt Dual Ext. Driven roll Equipment 2 Lubrication EP-2 grease 30 Sec Operator skiver bearing failure Inside pull 3 Inspection Head stock No damage 5 Sec Operator UNSAFE out ring Mr. Deepak Sahoo Consultant
  46. 46. VISUAL CONTROLS Activity Symbol Tools CLEAN I LUB SINSPECTION NOC Mr. Deepak Sahoo Consultant
  47. 47. Indication marks Indication for for nuts & bolts valve controls Mr. Deepak Sahoo Consultant
  48. 48. Arrow sign for Fan to indicate the indicating thefunction of Chiller Unit rotating direction of Motor Mr. Deepak Sahoo Consultant
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  53. 53. Avoid such extremes with some over enthusiastic teams Mr. Deepak Sahoo Consultant
  54. 54. Purpose of Step-4Bringing up equipment consciousness in the process of measuring & restoringdeterioration.To understand structures, functions & principles of equipment & learn theiroptimal conditions to thoroughly check principal mechanisms & parts of theequipment Mr. Deepak Sahoo Consultant
  55. 55. Preparation for Education & TrainingIdentifying general Inspection ItemsBasic Items: Machine Elements Lubrication system Bolts & Nuts Hydraulic System Pneumatic System Driving Systems Electrical systems Equipment Safety Process ConditionsAdditional Items: Specific to the EquipmentPreparation of text for General Inspection Education & Training Schedule Planning for General Inspection Education & Training Mr. Deepak Sahoo Consultant
  56. 56. Implementation of General Inspection Education & Training Implementation of Education for Circle LeadersPreparation of education transmission to Circle MembersImplementation 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
  57. 57. 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
  58. 58. 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
  59. 59. Initial Clean-up( Cleaning is Inspection)( Cleaning with meaning)(Doing with purpose)Taking countermeasurefor forced deteriorationand improving hardto access areaPreparing tentativestandards for cleaningand lubrication Mr. Deepak Sahoo Consultant
  60. 60. Four Steps to Become An Operator Strong on Equipment And Autonomous MaintenanceAutonomous Four steps toMaintenance become an operator7 steps strong on equipment 7 All-out autonomous management 4 Master how to repair the equipment Learn how to operate the 6 Orderliness and tidiness equipment with the required 3 accuracy and how to evaluate the product quality 5 Autonomous check-up 4 General inspection Study the mechanism and 2 functions of equipment and 3 Formulation of clean-up and lubrication standards machines 2 Measures against sources of outbreaks Familiarize with the concept of equipment maintenance and 1 improvement and with how to put the 1 Initial clean-up idea into practical realization Mr. Deepak Sahoo Consultant

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