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TPM-QM-Training Material as Per JIPM Methodology
- 1. TPM Club India Quality Maintenance Pillar Confederation of Indian Industry 1 Hinshitsu Hozen or Quality Maintenance PILLAR
- 2. TPM Club India Quality Maintenance Pillar Confederation of Indian Industry 2 “Hinshitsu-Hozen” What is “Hinshitsu-Hozen? To maintain integrity of quality (state of 100% non-defectives) * Condition setting : Set conditions for zero defects aimed at equipment and processes that do not produce quality defects. * Daily and periodical inspections : Inspect and measure conditions in time series. * Quality preventive maintenance : Prevent quality defects by maintaining measured values within the standard * Trend control and predictive maintenance : Predict possibilities of quality defects occurring by observing trends of measured values. * Prior countermeasures: Take measures beforehand © JIPM, 1994
- 3. TPM Club India Quality Maintenance Pillar Confederation of Indian Industry 3 Procuring/Producing materials not to generate defects Manufacturing equipment not to generate defect Devising methods not to generate defects Fostering operators proficient in equipment and job Jishu-Hozen activities Skill Education and Training + PM Analysis Pursue relationship between quality characteristics and material and energy condition / equipment precision / method conditions Maintenance and management ability training (Ability to find cause system troubles and to quickly and correctly take actions) Set conditions of equipment not to generate defects Management of conditions not to generate defects (Hinshitsu – Hozen) Zero quality defects Caused by raw material conditions Caused by equipment precision Caused by method conditions Caused by conditions of people involved Quality Defect Factors Hinshitsu – Hozen Concept © JIPM, 1987 Quality Assurance + Equipment and environment management Design check Material Management
- 4. TPM Club India Quality Maintenance Pillar Confederation of Indian Industry 4 Implementation Procedure for Quality Maintenance • Understanding quality defect phenomena. • Prepare QA Matrix. • Set 4M conditions. • Identify Process Point. • Conduct PM Analyses. • Identify Q-components • Prepare QM Matrix.
- 5. TPM Club India Quality Maintenance Pillar Confederation of Indian Industry 5 QM Master plan Master Plan for quality maintenance is planning of various activities in this pillar with respect to the time frame in months and years. According to the stage of TPM implementation it can start at various levels. In the beginning it will start with data collection on defects to improving conditions to sustaining zero defect conditions.
- 6. TPM Club India Quality Maintenance Pillar Confederation of Indian Industry 6 TPM Steps for QM-Pillar Step-1 : Understanding the Defect -Q Characteristics -Defect Characteristics -Defect Mode -Defect Phenomenon. -Data Collection. Step-2: QA Matrix - Defect Mapping - Defect Characteristics Vs Sub process - Defect Mode Vs Support Process. Step-3: Analyse 4M conditions. - Prepare draft of 4M conditions. - Status of 4M conditions. - Survey of 4M conditions. - Identify the gaps in 4M conditions. Step-4,5 & 6: Problem countermeasure and restoration. - Why-Why Analyses . - Quality improvements through Kaizens. - PM Analyses. Step-7,8 & 9: - Component Function - Identify Process Point. - Identify Q-components. Step-10: QM Matrix
- 7. TPM Club India Quality Maintenance Pillar Confederation of Indian Industry 7 Defects classification A - Type defect B - Type defect C - Type defect OK OK NOT OK Action taken by operator OK OK NOT OK No action by operator LSL USL LSL USL OK OK NOT OK Action taken by operator LSL USL • The output is (OK) initially • Becomes (NG) • Corrective action is taken by operator • Becomes (OK) • Uue Why – Why Analysis • The output is (OK) initially • Becomes (NG) • No action taken by operator • Becomes (OK) • Use PM Analysis • The output is (NG) initially • Action taken by operator • Becomes (OK) (setting scrap)-Why-Why
- 8. TPM Club India Quality Maintenance Pillar Confederation of Indian Industry 8 1. Quality Characteristics (From Customer or for customer). For e.g. Smooth Shifting of gears. 2. Defect Characteristics (Not achievement). E.g.-Shifting not ok/Shifting Bad. 3. Defect Mode (Modes of defect Characteristics). E.g- Shifting hard, shifting loose. Understanding Defect Phenomenon Defect Phenomenon is defining the defect characteristics in the form of defect mode. Phenomenon can be defined in 5W & 1H style (means What, Where, When, Which, Who, How much)
- 9. TPM Club India Quality Maintenance Pillar Confederation of Indian Industry 9 QA Matrix is prepared to establish the relationship between defect / defect mode and the process which causes it. It requires data collection for defects at various process stages to prepare a QA Matrix. Drafting of QA (Quality Assurance) matrix and reflection in standards
- 10. TPM Club India Quality Maintenance Pillar Confederation of Indian Industry 10 QA Matrix Process Sub-Process Support Process Quality Characteristics-Proper tightening of bolt Quality Index (Process) Defect Characteristics- Improper tightening Defect Modes Mode-1 Bolt loose Mode-2 Excess Tightening Mode-3 Bolt broken Mode-4 Washer flared Rear Wheel Fitment Nut Runner Air-Pressure √ √ √ √ 4 Tightening speed √ √ √ √ 4 Torque wrench Torque value √ √ √ √ 4 Bolt Bolt size √ X √ X 2 Washer Washer Size X X X √ 1 Quality Index (Defect) 4 3 4 4 15
- 11. TPM Club India Quality Maintenance Pillar Confederation of Indian Industry 11 Nut Runner Air-Pressure Maintain Air-pressure 6bar Ensure tightening of bolt upto last thread Dial Gauge with 6bar - - Tightening speed Ensure tightening speed 100RPM - - Speed Setting at 100RPM - - Torque wrench Torque value Ensure torque value- 150NM Apply torque till torque wrench click Torque value setting- 150NM - - Bolt Bolt size - Use correct bolt Engagement of initial thread Ensure size M20*1.25 Washer Washer Size - Use correct washer - Ensure no rust on bolt - - - - - - Ensure no thread damage Status 4M Condition Rear Wheel Fitment Bolt Broken Status Man Condition Status Method Condition Status Material Condition Process Sub-Process Support Process Defect Mode Machine Condition Status No Standard available 5 Standard available but not present at shop floor 0 Standard available but not followed 4 Standard available and followed 6 Legends:
- 12. TPM Club India Quality Maintenance Pillar Confederation of Indian Industry 12 Why-Why Analyses Sheet-Defect Product Date Time: Machine M/c No. Defect Phenomenon Previous Occurance Why Due to Date: Why 1 Effectiveness (Why Not OK) Why 2 Counter measures Details Why 3 Why 4 Why 5 Root Cause Root Cause Due to Tick Root Cause (Due to) Tick Particulars 1. Poor Basic condition Man Kaizen Idea No. 2. Poor Operating condition Machine OPL No. 3. Deterioation Material PM Calender 4. Weak Design Method Jishu Hozen 5. Poor Skill Horizontal Deployment Possible Yes/No Prepared by Department Head
- 13. TPM Club India Quality Maintenance Pillar Confederation of Indian Industry 13 Component function Analyses Machine-Systems-Assemblies-Components Actual Failure is Component failure not the machine. Defect-Component malfunction-Component failure. Part Name Function Problem/Defect Caused Extent of function degradation Inspection period specified/actual
- 14. TPM Club India Quality Maintenance Pillar Confederation of Indian Industry 14 Process Point Analyses Report
- 15. TPM Club India Quality Maintenance Pillar Confederation of Indian Industry 15 Quality Component
- 16. TPM Club India Quality Maintenance Pillar Confederation of Indian Industry 16 QM MATRIX: Cell: CT Old line Machine:DRM 02/03 Operations : Drilling & Reaming Machine Members Spindle Slide and index table Belts Plateform Clamps Syste m Spindl e head Cuttin g Tools Roller s Cuttin g Head Guide Bush and Jig Restin g pads Rack & Pinion Locatio n pin Product Characteristics Complaince Machine Inspection Items Inspection Item Run out of spindle near to face Axial play of Spindle-- Drill & Reamer End air butting Tesnsion of belt Cleani ng at restin g pads Air at outlet Press ure Locki ng with piston rod adapt or Press ure Oil level Tools condit ion Rollin g Move ment Feed Bush size Align ment Flatne ss Play b/t rack and pinion Diamet er Drilling Unit-A -1 Drilling Unit-A -2 Ream er Unit-B- 1 Ream er Unit-B- 2 Drilling Unit-A -1 Drilling Unit-A -2 Ream er Unit-B- 1 Ream er Unit-B- 2 Table- stn1 Table- stn2 Table- stn3 Table- stn4 Unit-A Unit-B Measurement Method Dial Dial Dial Dial Dial Dial Dial Dial Filler gauge Filler gauge Filler gauge Filler gauge Manua lly Manua lly Visual and physic al Physic ally Pressu re gauge Visual Pressu re gauge Visual at capplil ary tube Visual Manua lly Visual Plug gauge Gauge Dial Dial Microme ter Specification 0.02 to 0.025 mm 0.02 to 0.025 mm 0.02 to 0.025 mm 0.02 to 0.025 mm 0.01 to 0.015 mm 0.01 to 0.015 mm 0.01 to 0.015 mm 0.01 to 0.015 mm 0.025 Max 0.025 Max 0.025 Max 0.025 Max By pressi ng manua lly By pressi ng manua lly No chips No restrict ion in air 35-40 Kg/cm 2 Lockin g pin presen ce and inserte d properl y 40- 45Kg/c m2 Visible in capilar y tube No Blunt or wear out No jammi ng 86mm/ min No Go not to Qualify Conce ntric to each other within .010 mm 0.010- 0.015 mm 0.7495'' ±.0001 Frequency Weekl y Weekl y Weekl y Weekl y Weekl y Weekl y Weekl y Weekl y Weekl y Weekl y Weekl y Weekl y Weekl y Weekl y Every Comp onent Shift start Shift start Shift start Shift start Shift start Shift start Daily Weekl y Weekl y Daily Weekl y Weekl y Weekly Responsible Department Mainta inance Mainta inance Mainta inance Mainta inance Mainta inance Mainta inance Mainta inance Mainta inance Mainta inance Mainta inance Mainta inance Mainta inance Maint Maint Produc tion produc tion produc tion produc tion produc tion Produc tion Produc tion Produc tion Produc tion Engg Engg Engg Engg Engg Responsible Designation Manag er Manag er Manag er Manag er Manag er Manag er Manag er Manag er Manag er Manag er Manag er Manag er Manag er Manag er M/c Operat or M/c Operat or M/c Operat or M/c Operat or M/c Operat or M/c Operat or M/c Operat or M/c Operat or Manag er Manag er Manag er Manag er Manag er Manage r Checklist Used PM_Q M sheet PM_Q M sheet PM_Q M sheet PM_Q M sheet PM_Q M sheet PM_Q M sheet PM_Q M sheet PM_Q M sheet PM_Q M sheet PM_Q M sheet PM_Q M sheet PM_Q M sheet PM_Q M sheet PM_Q M sheet CLIT Sheet CLIT Sheet CLIT Sheet CLIT Sheet CLIT Sheet CLIT Sheet CLIT Sheet CLIT Sheet MPA PM of Jig Fixture s PM of Jig Fixture s PM of Jig Fixture s PM of Jig Fixture s PM of Jig Fixtures Quality Characterist ic on Product (KMC CTQ) Concentricit y R70-3 to R70-1 at 15'' 0.12mm p p p p p p p p p p p p p p p p p p p p p Concentricit y R71-3 to R71-1 at 15'' 0.12mm p p p p p p p p p p p p p p p p p p p p p Concentricit y R72-3 to R72-1 at 15'' 0.12mm p p p p p p p p p p p p p p p p p p p p p Concentricit y R73-3 to R73-1 at 15'' 0.12mm p p p p p p p p p p p p p p p p p p p p p Process Characteristics Compliance QM Matrix: To relate the malfunction of component (abnormality ) with defect mode.