The document focuses on 'Kobetsu-kaizen' as a method for improving production efficiency through individual improvements targeting zero losses in manufacturing systems. It outlines structured procedures for implementing these improvements, structured into phases and emphasizing analysis of various types of production losses including setup, startup, speed, and yield losses. Key strategies involve analyzing causes of failures and losses, enhancing maintenance practices, and improving equipment and operational efficiency.

1. 1
TPM for lean manufacturing
Chap３． Kobetsu-kaizen for production efficiency
Quote From ：TPM Deployment program
TPM encyclopedia Keyword Book
（Japan Institute of Plant Maintenance)
Created by Japanese Gemba Kaizen Web

2. 2
３． Kobetsu-kaizen for production
efficiency
3.1 ・・・ Improvement of zero failure ・・・・・P38
3.2 ・・・ Improvement of the setup ・・・・・P43
3.3 ･･･ Improvement of cutting blade change loss・・・47
3.4・・・ Improvement of start up ・・・・・P50
3.5・・・ Improvement of Minor stoppage ・・・・・P52
3.6・・・ Improvement of Speed losses ・・・・・P56
3.7・・・ Improvement of Yield losses・・P58
3.8・・・ Principle of improvement ・・・・・・P60

3. “Kobetsu-Kaizen" refers to the “individual
improvement for further efficient
production systems." It means efforts to
select model equipment or a model line
and to challenge the target of zero losses
through project team
activities according to improvement
themes.
“Kobetsu-Kaizen" takes the form of
activities through project teams composed
of managerial staff members and through
small workshop
groups.
The procedures for the implementation of
“Kobetsu-Kaizen" by managerial stall
members are as follows:
[1] Selection of model equipment
Model equipment or a model line should be
chosen.
[2] Organization of a project team
A team of several members should be
organized, with the line manager in
charge of the model equipment serving as its
leader.
[3] Grasping and confirmation of 16 major
losses
[4] Decision on the theme and preparation of a
promotion program
[5] “Kobetsu-Kaizen" project activities
For these activities, failure analysis methods
and IE methods should be
utilized. For chronic losses, PM analysis should
be applied.
[6] Standardization and horizontal evolution
should be completed for enhancement of OEE
3

4. 4
３．１ Improvement of zero failure
３・１・１ Common challenges related to failure
(1) No interest production Section
・ The worker is not anything other than work
・ For safety reasons, worker does not touch the equipment
・ There is no provision
(2) Failure analysis is poor
・They have not drawn broken parts
・ They dose not have to disassemble the defective part
・They only exchange parts
・No relapse prevention
Workers just do not know how to Maintenance
If Teach Maintenance to Wokers ,They can .
Maintenance personnel does not understand the function of the parts
They does not understand Why-Why analysis

5. 5
(3) Maintenance system is incomplete
・Judgment standard ,method of inspection , inspection points is incomplete
・Defective Maintenance schedule
・ Record system of failure
(4) Predictive maintenance is poor
・Periodically measuring equipment to determine the abnormality
・ Precision diagnosis ・・・Measure vibration, current load, timing, operating time,
sound, etc and then understand the change point
If there is no data management can not be right!

6. 6
３・１・２ Thinking reduction of failure
(1) Classification of failure
・failure Classified simple and complex then Give priority to simple failure
・ Method of stratified ・・・Mode causes / line/Occurrence location
(2) Failure analysis
・Stress on the equipment
→ Electric or mechanical stress, temperature, humidity, dust, vibration,
Cause failure ：
· deficiencies basic conditions
· Do not keep the terms and conditions
· Degraded without Restore
· lowering skill
· Lack of design
Intensity <Stress
Failure occurrence
To educate and Change the way of thinking
and Change their behavior

7. ３･1・３ Four phases to achieve zero failures
Four phases to achieve zero failures
A short-term and simultaneous implementation
of the five measures for zero breakdowns is
unlikely to progress smoothly. It is more effective
to divide enforcement of the measures into four
phases and implement them one by one under a
plan. Through these steps, steady approach to
zero failures will become possible.
The four phases and principal themes of
individual themes are as follows:
~ Phase 1: To reduce dispersion of MTBF —
mean time between failures.
Repair of previous uncovered but unamended
degradation to restore the original conditions,
preparation of basic conditions, and
prevention of artificial machine deterioration
through observance of usage conditions.
- Phase 2: To extend inherent service life.
Improvement of design shortcomings (corrective
maintenance),prevention of random failure
occurrences due to operation or repair errors,
and restoration by fixing external appearance
deterioration.
- Phase 3: To periodically repair deterioration to
restore original conditions.
Regular deterioration repair to restore the
original conditions
periodic maintenance: TBM), and grasping of
abnormal symptoms
of internal deterioration based on the five senses.
- Phase 4: To foresee the service life.
Prediction of the service life based on condition
diagnosis
techniques (predictive maintenance: CBM), and
technological
analysis of catastrophic failures.
7

8. ３･1・４ Five measures to achieve zero failures
Failures represent only the tip of the iceberg, so
to speak. The leaving of
latent defects below the “water surface" causes
failures.
Methods for uncovering such latent defects and
preventing failures are the
"five measures to achieve zero failures, "and
they are as follows:
[1] Put basic conditions in place:
Keeping of basic conditions for equipment, i.e.,
enforcement of cleaning,oiling, and retightening
(of bolts and nuts).
l2] Abide by operational conditions:
Observance of the specified operational
conditions of the equipment, such
as pressure, temperature, speed, and flow rate.
[3] Restore original functions by fixing
deterioration:
The prevention of forced deterioration of
quipment is possible by preparing basic
conditions and abiding by usage conditions.
Even so,natural deterioration, such as wear,
corrosion, fatigue, and declining insulation,
inevitably occurs. Therefore, such deterioration
should not be left unattended but corrected to
restore the original conditions.
l4] Improve design weaknesses:
Only repeating correction of deterioration cannot
lead to progress. To begin with, deterioration
may be accelerated due to material selection
errors or structural defects during design stage.
Such design shortcomings must be rectified
(this is corrective maintenance).
' l5] "Improve skills:
8
Ask to
the machine
cleaning,oiling, and retightening is Important

9. 9
３．２ Improvement of the setup
This is one of the seven major losses that
impede equipment operations and
refers to the time lost from the
termination of the production of a
present item until the good-quality
manufacturing of the next item
subsequent to setup and adjustment.
The setup here means a series of work:
removal of jigs/tools upon the completion
of the on-going production, clearing up,
cleaning; preparation,attachment,
adjustment, and measurement of
jigs/tools required for the next item
and manufacturing of non-defective
products.
There remain many issues to be
addressed to shorten the time spent
on ‘internal setup’ (setup during
machine stoppage) and ‘external
setup’ (setup without machine
stoppage) based on IE approach.
Adjustment means the following:
[1] Measures to be taken to seek the
optimum solutions or values to attain
some purpose; for instance, the
procedures to put quality within
designed values
[2] What is achieved through the
repetit ion of trial and errors
Understand the setup, to quantify ！

10. 10
(1) Organize and tidy
・ Management position of tooling
・ Do not search, do not move
(2) Clarification External setup and Inter
setup
・ Study Elimination of work-
・ Review of work procedures
(3)Study External setup to Inter setup
・Preset(Pre-assembled)
・ Sharing of jig and Exchange one-touch
・ Changes the adjustment to External
setup
・Using the auxiliary jig・・・The elimination
of adjustment
(4) Study procedures of Inter setup
・Study on method of fixation Screw fixing
→ Hydraulic
・ One worker → Two worker Time
savings
(5) The elimination of adjustment
· The purpose of the adjustment
① positioning
② centering
③ the correct dimensions
④ timing
⑤ balance
-Cause of the adjustment
① cumulative error
② shortage standardization
③ shortage rigidity
Analysis of adjustment
Study the one-touch setup
Study eliminating waste of External setup and Inter setup
３・２・２ Improvement of the setup

11. 11
Viewpoint Improvement of setup
5S, preset, standardization, into fixture, no adjustment

12. 12
One-touch attachment and Analysis of adjustment
The elimination of adjustment
→ One-touch attachment

13. 13
３．３ Improvement of cutting blade change loss
３．３．１－ Problem of cutting blade
（１）The life of the cutting tool
・Shape and material of the cutting tool
· Cutting conditions (cutting speed)
・Material, hardness
・requirements of Quality product
(Dimensional accuracy, surface roughness)
・Rigidity of the equipment
Look the cutting edge！

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（２）Exchange conditions
Reason:
・Unclear Exchange standards
・Failure occurs,
Exchange without permission
（３）Inhibiting unattended operation
Reason:
・varies Quality ・Short-cutting tool life
・Occurs Minor Stoppage
（４） Reduction of cutting tool’s cost
・Storing the old chip
・ No management objectives of cost cutting tool
・ Many kinds of cutting tool
・Management chip is loose
・ No historical record use of a chip
・ No Management abrasion of the chip
(Can be use but exchange can not use but No exchange)

15. 15
Detection parameters of the cutting tool life
Quantify sound, vibration, AE, resistance, current, heat

16. Start-up losses denotes the time losses and
volume losses (from defects and remark)
until product quality stabilizes to
manufacture non-defective products even in
accordance with the specified cycle time
without mechanic troubles, such as minor
stoppages, small troubles, and breakage of
cutting blades, during
[1] start-up after periodic overhaul
[shutdown maintenance]
[2] start-up after downtime (long-term line
stoppage)
[3] start-up after holidays
[4] start-up after the lunch break.
At a machining shop dimension dispersions
are likely to occur during the morning setup,
causing frequent adjustments, rework due to
failure to
adjustment, and breakdown of cutting
blades. To prevent these, warm-up and
idling operations are conducted early in the
morning. The target of
start-up losses is “minimization.”
16
3.4 Improvement of start up
Understanding the thermal displacement!!

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3.4.2 Improvement Way of start up
(1) measure：
・Measuring temperature of the table, Main shaft, etc to stabilize.
(2) Study Material ：
・Consult the manufacturer the material to minimize thermal displacement
(3) Cooling the generator
・ Cool heat by Cooling fan
(4) Automatic correction
・Automatically adjusts to predict beforehand the amount of displacement
Study Cause,Thermal displacement curve,Time to settle

18. 18
3.5 Improvement of Minor stoppage losses
[1] In case temporary functional
stoppage ensues.
[2] in case the recovery of functions is
made by simple fixing
(elimination of abnormal work-
piece and/or resetting)
[3] ln case parts exchange or repair
are not required.
[4] Recovery time lasts from 2 or 3
seconds less than 5 minutes.
Unlike failures, minor stoppage/idling
losses represent a status in
which the machine is subjected
to either stoppage or idling due
to temporary troubles; for
instance, when a work-piece is
clogged in the chute, idling
occurs ; or when a sensor activated
because of a quality defect to
cause a temporary stoppage.
These are the conditions in which the
machine will revert to normal
operation, if the stuck work-
piece is removed, or resetting is
carried out. Therefore, they are
fundamentally different from
machine failures.
To reduce minor stoppages, it is
important to in detail analyze
phenomena [or slight defects]
and to thoroughly eliminate
slight defects.
Observation, analysis, stratified to investigate at the site

19. 19
3.5.2． Improvement Way of Minor stoppage
losses
(1) Phenomenon analysis and motion analysis of workpiece:
Video recording the phenomenon of Minor stoppage , Viewpoint is movement
posture, angle, float, vibration
(2) Remediation of the defect:
Contact surface of the workpiece is key point
Improve the small defects of parts and jigs
（３）Compliance with the basic maintenance：
Cleaning, refueling, retightening
（４） Compliance with of the basic tasks：
Correct operation, setup, adjustment
（５）Study on optimum condition：
Studied the optimization of processing conditions of Parts
（６）Study Weakness:
Studied the problem of the design of equipment、parts,jigs
Understand the movement of the workpiece by video shoot

20. 20
Classification of phenomenon
and Classification of causes

21. 21

22. 22
３．６ Improvement of Speed losses
Into the data to understand the current status of equipment!
One of the seven major losses impeding
efficiency improvement of equipment. These
losses incurred by slow machine speed are
defined as
follows:
[1] Losses due to the difference between the
actual speed and the design
speed (or reference speed for each product
item)
[2] Losses resulting from lower design speed
compared to the present technological level or
desirable speed
(or ‘mission’ speed)
As an example of the former case, the cycle
time is 60 seconds as reference but the actual
operation cycle time is 65 seconds. There is a
speed loss of 5 seconds. As an example of the
latter case, the cycle time is set at 60 seconds
but it could be reduced to 50 seconds through
improvement based on the current
technological level. There is a speed loss of
10 seconds in this case.
Aiming at speed increase would contribute to
clarification of problems and
upgrading of technological levels. Therefore,
the target should be to make
nit the difference between the design speed
and the actual speed.

23. 23
３．６．２ How to improve the speed loses
（１）Understand the cause
To speed up For the experiment.
① Changes in Cp ？
② New bad item ？
③ The life of the cutting tool ？
④ Number of occurrences of Minor Stoppage？
⑤ Percentage occurrence of defective ？
＊Examine the aggravating factors measures ahead
（２）Check the validity of the action
①Reduction of air cut time
②Reduction of idle time ③Reduction of operating time ④ Reduction of working hours by two
people work
＊Make improvement on equipment mechanism, component structure, timing, the cycle diagram.
Study Air cut time,Idle time,Operating time,Two person work

24. 24
３．７ Improvement of Yield losses
This refers to the volume losses resulting from
differences between raw material weight
and product weight, or between raw
materials input and product weight.
The former represents material losses that can
result from leaving too much iron cast for
fear of casting shortcomings (such as sand
inclusion) or from forging too thick so that it
may be sufficient enough to obtain mold
precision in the shaping process.
As a result of these, cutting time can be
lengthened, or the service life of cutting
blades shortened.
The latter represents the difference between
whitewash weight, gate weight, generated
burr volume and the product weight. in
other words, the losses in this category
result from increased burr generation due
to molding precision insufficiency.
in the case of aluminum casting, this refers to
the
losses representing runner weight and blur
Weight.

25. 25
３．７．２ How to to reduce chronic defects
（１）Immobilization of variable factors
factors?:Impact phenomena logically
Cause？：Which have proved to have influenced the phenomenon
“Restore ,For Immobilizing the "Variation factor"!！

26. 26
３．８ Principle of improvement

27. 27
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