JISHU HOZEN is TPM pillar, Not complete slides

1. JISHU- HOZEN
Prevent the occurrence of 1A/1B because of JH.
Reduce the OIL consumption by 50%.
Reduce Process time by 50%.
Increase use of JH by 50%
8. Autonomous Management
7. Standardization
6. Autonomous Inspection
5. General Inspection
4. Fix Tentative JH Stds
3. Take Counter Measures
2. Initial Cleanup of Machine
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
1. Prep of Employees
1

2. JISHU- HOZEN
Autonomous Maintenance
7 steps
7. Autonomous Management
6. Standardization
5. Autonomous Inspection
4. General Inspection
3. Develop Tentative Standards
2. Counter Measures against Source & Kaizen
1. Initial Cleaning and Tagging
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
2

3. JISHU- HOZEN
Autonomous
Maintenance
PROCESS
5. Autonomous Inspection
4. General Inspection
3. Develop Tentative Standards
2. Counter Measures against Source & Kaizen
1. Initial Cleaning and Tagging
1. Manage Model Team
2. Manage Model Machine
3. Implement 5S
4. STEPS 123
5. Kickoff
9. Go to Step 4&5 and continue
8. Deployed to other M/C
7. Steps 123 with Audits
6. Forms Autonomous
Maintenance Teams
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
3

4. JISHU- HOZEN
WHY
Autonomous
Maintenance
1. Minor Stoppage Loss
2. Reduced Speed Loss
3. Breakdown Loss
4. Setup & Adjustment Loss
Preventive
Maintenance
Production
Maintenance
American Style of PM
TPM
Japan Style of
PM
Maintenance Departments Sole
Responsibility
9. Confirmation of working conditions
10. Daily Inspection / Periodical Inspection
10. Activities to prevent eqpt degradation
5. Yield Loss
11. Activities to keep record on eqpt degradation
6. Defect Quality Loss
12. Keep cleaning, Inspection, Additional light
7. Poor Skills of Operator
8. Improper Position to Conduct Inspections
13. Activities to restore the machine
conditions
14. Frequent Servicing, Solution of abnormality,
Good Communication
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
4

5. WHY
JISHU- HOZEN
1 To establish basic equipment condition
2. To make operator familiar with his equipment
3. To prevent equipment deterioration
4. To maintain in optimal condition
5. To eliminate equipment failure
6. To eliminate quality defect
7. To eliminate cost losses
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
5

6. JISHU- HOZEN
The Mind
Set
1. Indl preserving one’s own eqpt
2. Significant Change from early theory of “ I mfr - U Repair” or
“ I make – U Fix”
Production indls Thoughts
Maintenance indls Thoughts
Maint does NOT its Job
Production do not know how to operate
Maint staff take took long to fix job
This eqpt is so OLD no wonder it breaks
down again & again
We get lot of repairs so we don’t have ample
to do a Real corrective and are forced to do
only temporary job
We are too busy to do vital daily checks
We Prep the stds but they do not do the
Prep by Tanveer Ahmed, BE,ME Textile,
checks
MS/Mphil Quality Managements (Industrial
Management)
6

7. JISHU- HOZEN
Three Key Tools for Autonomous
Maintenance
Key Concepts:
Shop Floor Based Activities
Operator Conducted
Operator Enhancing
Team Activity
 Autonomous Management
TPM Foundation
Part of the Job
Activity
Board
Meetings
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil
Quality Managements (Industrial Management)
One
Point
Lesson
7

8. Activity
Board
JISHU- HOZEN
Three Key Tools for Autonomous Maintenance
People
Activity & Findings
Treasures
Team & Team Mission
Step1initial Cleaning
Display Actual Findings from initial
cleaning, such as Trash, Unnecessary
Items, Dust and other contamination
Line Layout & identified
important areas
-Definition
-Pics before / after
Step 2Source of Contamination
“ Explain & show Focused
Improvement activities for Source of
Contamination”
-Safety Hazard
- Contamination
- Hard –to - Reach
- Maint Failure
- Tag List Production/
Maintenance
- Tag Movement / Actual tags
One Point Lesson
Prep by Tanveer Ahmed, BE,ME Textile,
MS/Mphil Quality Managements (Industrial
Management)
8

9. Activity
Board
JISHU- HOZEN
Three Key Tools for Autonomous Maintenance
Dept / Line:
Bldg Y
Area: Bag
Printer
Mach ID
Diagram
No.
Criteria
Items
Date: 4/28 Tag
/14
Method
Tools
T(Min)
Prep by Tanveer Ahmed, BE,ME Textile,
MS/Mphil Quality Managements (Industrial
Management)
Freq
Person Resp
9

10. One
Point
Lesson
JISHU- HOZEN
Three Key Tools for Autonomous Maintenance
One Point Lesson is a tool with the
Following Characteristics:
Contents can be
knowledge and skills
of
1.
2.
3.
4.
1. One Sheet
2. To Share the results of autonomous
study
3. For 5-10 minutes
Equipment
Safety
Operation Process
Task
Prep by Tanveer Ahmed, BE,ME Textile,
MS/Mphil Quality Managements (Industrial
Management)
10

11. JISHU- HOZEN
Equipment
Deterioration
Natural Deterioration
(Extend Life Time)
ACCELERATED Deterioration
(Eliminate Cause)
Corrective Maintenance
Prevent errors by
IMPROVING Operability &
Repair Quality
Improve Maintainability &
Repair Quality
Improve Safety & Reliability
Establish Basic Conditions
Cleaning : Eliminate all dust
& Dirt
Lubricating : Keep lubricants
clean and replenished.
Tightening: Keep Nuts &
Bolts secure
Prep by Tanveer Ahmed, BE,ME Textile,
MS/Mphil Quality Managements (Industrial
Management)
11

12. JISHU- HOZEN
Classification of Maint Activities
A. Activities to prevent deterioration
By correct operation , improvement of
basic conditions & adjustments to
prevent quality defects.
B. Activities to MEASURE deterioration
By Senses (touch, see, hear, smell)
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 problems & MP design.
- Play role in B by five senses
-Play role in C by prompt reporting &
assisting in sporadic failure.
-Play role in as a guide & educationist & providing
help in identifying areas “ sources of problems &
“Hard to Clean”
- Play in role B by vibration & fluid analysis.
- Play major role in C by improving MTBF, MTTR.
-Besides that they maintain MIS , work for new
equipment design & setup maintenance stds.
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil
Quality Managements (Industrial Management)
12

13. JISHU- HOZEN
STEP - 0
.
Initial Preparation
Prep of JH Activities
1. Prep a Cleaning & Lubrication Map
2. Arrange Tools
3. Arrange Red & White Tags
4. History of Failures
5. Training on 7 Steps of Jishu Hozen
6. Gant Chart
7. Training on 7 Types of abnormalities
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil
Quality Managements (Industrial Management)
13

14. JISHU- HOZEN
STEP - 1
Initial Cleaning
1. Cleaning is Inspection
5. Make the List of
2. Use 5 Senses for Cleaning
3. Find out 7 Types of Abnormalities
4. Put Tags on Abnormalities
Hard to Clean
Hard to Lubricate
Hard to Tighten
Hard to Inspect
Hard to Adjust
Record cleaning time
Carryout Audit on 1st Step
Meeting after the Daily Activities
Refers to the Old History Records
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil
Quality Managements (Industrial Management)
14

15. JISHU- HOZEN
STEP - 1
Initial Cleaning – 7 Types of Abnormalities
2. Sources
1. Minor Flaws
Contamination
Quality Defect
2. Places
1. Unfulfilled Basic Conditions
In Accessible
Unsafe
1. Items
Prep by Tanveer Ahmed, BE,ME Textile,
MS/Mphil Quality Managements (Industrial
Un-necessary – Non Urgent
Management)
15

16. JISHU- HOZEN
STEP - 1
Initial Cleaning – 7 Types of Abnormalities
1.Minor Flaws
Contamination
Dust, Dirt, Powder, Oil, Grease , Rust, Paint
Damage
Bending, Cracking, Crushing, Chipping, Deformation
Play
Shaking, Falling Out, Tilting, Eccentricity, Wear, Distortion,
Corrosion
Slackness
Belts, Chains
Abnormal
Phenomenon
Unusual Noise, Overheating, Vibration, Strange Smells,
Discoloration, Incorrect Pressure or Current
Adhesion
Blocking, Hardening, Accumulation of Debris, Peeling,
Prep by Tanveer Ahmed, BE,ME Textile,
MS/Mphil Quality Managements (Industrial
Malfunction
Management)
16

17. JISHU- HOZEN
STEP - 1
Initial Cleaning – 7 Types of Abnormalities
2.Unfulfilled Basic Conditions
Lubrication
Dirty, Insufficient, Unidentified, Unsuitable, Leaking
Lubrication Supply
Dirty, Damaged or deformed lubricant inlets, faulty
lubricant pipes
Oil Level Gauges
Tightening
Dirty, Damaged, Leaking, No indication of correct level.
Nuts and Bolts slackness, Missing, Cross-Threaded,
Too long, Crushed, Corroded,
Unsuitable washers, wing nuts on backward
Prep by Tanveer Ahmed, BE,ME Textile,
MS/Mphil Quality Managements (Industrial
Management)
17

18. JISHU- HOZEN
STEP - 1
Initial Cleaning – 7 Types of Abnormalities
3. Inaccessible Places
Machine Construction, Covers, Layout, Footholds, Space
Construction, Covers, Layout, Footholds, Instrument
position and Orientation, Operating – Range Display
Position of Lubricant Inlet, Construction, Height, Footholds,
Lubricant outlet, Space
Covers, Construction, Layout size, Space
Machine Layout, Position of Valves, Switches and Leavers,
Footholds
PositionTanveer Ahmed, BE,ME Textile, Thermometers, Flow
Prep by of Pressure Gauge,
MS/Mphil Moisture Gauges, Vacuum Gauges etc.
Meters, Quality Managements (Industrial
Management)
18

19. JISHU- HOZEN
STEP - 1
Initial Cleaning – 7 Types of Abnormalities
4. Unsafe Places
Floors
Unevenness, cracked, holes, projections, peeling, wear of
steel chucker plates, slipping.
Steps
Too steep, irregular, slipping, missing Hand rails
Lights
Dim, out of Position, dirty / broken covers,, no explosion
proofing etc
Displaced, Fallen oil / broken covers, not safe for
emergency, Missing emergency stop Devices
Rotating Machinery
Lifting Devices
Wires, Hooks, Brakes & Other parts of cranes and Hoists
Others
Special Substances,BE,ME Textile, Toxic gases, Insulating
Prep by Tanveer Ahmed, solvents,
MS/Mphil Quality Managements (Industrial
materials, danger signs, protective clothing etc.
Management)
19

20. JISHU- HOZEN
STEP - 1
Initial Cleaning – 7 Types of Abnormalities
5. Contamination Sources
Product
Leaks, Spills, Spurts, Scattering, Overflow
Raw Materials
Leaks, Spills, Spurts, Scattering, Overflow
Lubricants
Leaking, Spills, Seeping Oils, Hydraulic Fluids, Fuel Oils
Gases
Leaking compressed air/gases/steam/vapors/exhaust fumes
Liquids
Leaking Water/hot/cold, Half Finished Products, waste Water,
Leaking Supply lines
Scrap
Flashes, Cuttings, Packaging material and NC Products
Others
Contamination by people & Forklifts, Infiltration through
Prep by Tanveer Ahmed, BE,ME Textile,
MS/Mphil Quality Managements (Industrial etc.
20
cracked walls, broken windows
Management)

21. JISHU- HOZEN
STEP - 1
Initial Cleaning – 7 Types of Abnormalities
6. Quality Defect Sources
Foreign 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, Infiltration
Gain Size
Abnormalities in Screens, Compressed air separators,
Centrifugal Separators
Concentration
Viscosity
Inadequate Warming, Heating, Compounding, Mixing,
Evaporating, Stirring etc.
Inadequate Warming, Heating, Compounding, Mixing,
Prep by Tanveer Ahmed, BE,ME Textile,
MS/Mphil Quality Stirring etc.
Evaporating, Managements (Industrial
Management)
21

22. JISHU- HOZEN
STEP - 1
Initial Cleaning – 7 Types of Abnormalities
7. Un-Necessary and Non Urgent Items
Machinery
Pumps, Fans, Compressors, Columns, Tanksers
Piping Equipment
Pipes, Hoses, Ducts, Valves, Dampers etc.
Measuring
Instruments
Temperatures, Pressure Gauges, Vacuum Gauges, Ammeters
etc
Electrical eqpt
Wiring, Piping, power leads, Switches, Plugs etc.
Jigs & Tools
Gen Tools, Cutting Tools, Jigs, Molds, Dies, Frames etc.
Spare Parts
Standby eqpt, spares, permanent stocks, Auxiliary material
Makeshift Repairs
Prep String, Ahmed, BE,ME Textile,
Tape, by TanveerWire, Metal plates etc.
MS/Mphil Quality Managements (Industrial
Management)
22

23. JISHU- HOZEN
STEP - 2
Measure Against Sources
Counter Measure Against Source of Contamination & Hard to do CLRI
Counter Measure against source of contamination
Make approach easy for CLRI.
Make easy to do CLRI
Shorten, Cleaning & lubricating time.
Adopt concepts of localized guards.
Ranking the priority places for daily cleaning
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
23

24. JISHU- HOZEN
STEP - 3
Formulation of Cleanup and Lubrication Standards
Prepare Tentative Standards
Standards for Cleaning, Lubricating & Tightening
Standards are made by Operators themselves with
guidance by PM
Standards are Made by using 5W 1h
Standards should be Easily understood by every one
Introduce Extensive Visual Control.
Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)
24

25. Prep by Tanveer Ahmed, BE,ME Textile,
MS/Mphil Quality Managements (Industrial
Management)
25