Autonomous Maintenance (Jishu Hozen) by Ketan Kumar (Raavinnovate)

This file contains brief introduction about Autonomous Maintenance (a pillar of TPM) which also known as My Machine my concept. In this the Goal for AM, History of AM, Benefits of AM, OEE, 7 basic types of abnormalities and steps of Autonomous Maintenance are discussed along with pictorial examples, CLIT, SOP, etc are also illustrated.

1. Jishu Hozen (By Ketan Kumar) 1 By : Ketan Kumar [email protected]

2. By : Ketan Kumar 5 S KAIZEN PLANNED MAINTENANCE QUALITY MAINTENANCE TRAINING OFFICE TPM SAFETY, HEALTH AND ENVIRONMENT AUTONOMOUS MAINTENANCE PILLARS OF TPM 2 Jishu Hozen (By Ketan Kumar)

3. WHAT YOU KNOW ABOUT MY MACHINE-MY RESPONSIBILITY? Jishu Hozen (By Ketan Kumar) 3

4. EXPECTATIONS FROM THIS SESSION? Jishu Hozen (By Ketan Kumar) 4

5. Shift 4 sticks & Make 3 Squares….. 5 Jishu Hozen (By Ketan Kumar)

6. Solution Jishu Hozen (By Ketan Kumar) 6

7. CONTENT Jishu Hozen (By Ketan Kumar) 7 WHAT IS AM? MY MACHINE MY M/C CONCEPT WHY DO M/C FAILS HOW CAN YOU PREVENT M/C FROM BREAKDOWN CHALLENGES ABNORMALITY 7 TYPES OF ABNORMALITY STEPS OF AM VISUAL MAINTENANCE CONTROL CLIT BENEFITS OF AM

8. WHAT IS AM? Jishu Hozen (By Ketan Kumar) 8

9. MY MACHINE HOW DO YOU KEEP YOUR MACHINE TROUBLE FREE ? Jishu Hozen (By Ketan Kumar) 9

10. MY MACHINE HOW DO YOU KEEP YOUR MACHINE TROUBLE FREE ? Jishu Hozen (By Ketan Kumar) 10 Daily: Cleaning Hydraulic/Lubrication oil level Air Pressure Abnormal Sound Tightening

11. MY MACHINE HOW DO YOU KEEP YOUR MACHINE TROUBLE FREE ? Jishu Hozen (By Ketan Kumar) 11 Weekly: Tank Cleaning Oiling Checking of Nuts & Bolts Electric Panel Cleaning

12. MY MACHINE HOW DO YOU KEEP YOUR MACHINE TROUBLE FREE ? Jishu Hozen (By Ketan Kumar) 12 Monthly: Play in slides Bearing Noise Checking of Belts & Chains Cleaning of filters Preventive Maintenance

13. MY MACHINE HOW DO YOU KEEP YOUR MACHINE TROUBLE FREE ? Jishu Hozen (By Ketan Kumar) 13 3 Moths or 6 Months: Hydraulic Oil replacement Lubrication oil tank cleaning

14. WHAT IS MY MACHINE CONCEPT? Jishu Hozen (By Ketan Kumar) 14 It means that everyone carries out Routine Inspection Oiling Parts Replacement Repair Early detection of abnormalities Precision checking of their own equipment

15. WHY DO MACHINE FAILS?? Jishu Hozen (By Ketan Kumar) 15 Machine fails when they are not taken care of. Just like a human body, we fall ill when we don’t take proper care of our body. Similarly same is for the Machine also.

16. HOW YOU CAN PREVENT YOUR MACHINE FROM BREAKDOWNS? Jishu Hozen (By Ketan Kumar) 16 Timely cleaning and checking of the machines Knowing about failures before they occur Solving the problems immediately

17. CHALLANGES Jishu Hozen (By Ketan Kumar) 17

18. MY MACHINE Jishu Hozen (By Ketan Kumar) 18 In just 3 steps Step-0 Step-1 Step-2 Step-3

19. ABNORMALITY Jishu Hozen (By Ketan Kumar) 19 Anything that is not in the specifications of the machine manufacturer. Abnormalities:- dirty Loose Hanging Leaking Splashing/spilling Broken Excess length / heat / vibration Unwanted / missing Bent, holes, worn-out Abnormal noise

20. 7 TYPES OF ABNORMALITIES Jishu Hozen (By Ketan Kumar) 20 Minor Flaws Unfulfilled Basic Conditions Inaccessible Places Contamination Sources Quality Defect Sources Unnecessary & Non-Urgent items Unsafe Places

21. 1. Minor Flaws Jishu Hozen (By Ketan Kumar) 21 Abnormality Examples 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 Phenomenon Unusual noise, overheating, Vibration, strange smells, discoloration, incorrect pressure or current Adhesion Blocking, hardening, accumulation of debris, peeling, malfunction

22. 1. MINOR FLAWS Jishu Hozen (By Ketan Kumar) 22 OVER HEATING CHIPS CAN DAMAGE SLIDES BROKEN /DAMAGED GUARDS LOOSE FITTING

23. 2. UNFULLFILLED BASIC CONDITION Jishu Hozen (By Ketan Kumar) 23 Abnormality Examples Lubrication Insufficient, Dirty, Unidentified, unsuitable, Leaking Lubrication Supply Dirty, damaged or deformed lubricant inlets, faulty lubricant pipes Oil level gauges Dirty, Damaged, leaking, No indication of correct level Tightening Nuts and Bolts slackness, Missing, Cross-threaded, Too long, Crushed, Corroded, Unsuitable washers, wing nuts on backward

24. 2. UNFULLFILLED BASIC CONDITION Jishu Hozen (By Ketan Kumar) 24 CUTTING OIL OVERFLOW NO INDICATIONS OF LOW/HIGH WORN OUT PADS

25. 3. INACCESSIBLE PLACES Jishu Hozen (By Ketan Kumar) 25 Abnormality Examples Cleaning Machine construction, Covers, Layout, footholds, Space Checking Construction, Covers, Layout, footholds, Instrument position and Orientation, Operating – Range display Lubricating Position of lubricant inlet, construction, height, footholds, lubricant outlets, space Tightening Covers, Construction, Layout size, Space Operation Machine layout, Position of valves, Switches and leavers, Footholds Adjustment Position of pressure gauges, thermometers, flow meters, moisture gauges, vacuum gauges, etc.

26. 3. INACCESSIBLE PLACES Jishu Hozen (By Ketan Kumar) 26 HARD TO CLEAN HARD TO LUBRICATE HARD TO CHECK BELT CONDITIONS

27. 4. CONTAMINATION SOURCES Jishu Hozen (By Ketan Kumar) 27 Abnormality Examples Product Leaks, Spills, Spurts, Scattering, Overflow Raw materials Leaks, Spills, Spurts, Scattering, Overflow Lubricants 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.

28. 4. CONTAMINATION SOURCES Jishu Hozen (By Ketan Kumar) 28 MIXING OF CUTTING OIL & LUBRICATION OIL MIXING OF HYDRAULIC & CUTTING OIL

29. 5. QUALITY DEFECT SOURCES Jishu Hozen (By Ketan Kumar) 29 Abnormality Examples 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 Grain 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.

30. 5. QUALITY DEFECT SOURCES Jishu Hozen (By Ketan Kumar) 30 FULL OF CHIPS DENTS PROBLEM

31. 6. UNECESSARY & NON URGENT ITEMS Jishu Hozen (By Ketan Kumar) 31 Abnormality Examples Machinery Pumps, fans, compressors, columns, tanks etc. Piping equipment Pipes, hoses, ducts, valves, dampers etc. Measuring instruments Temperatures, pressure gauges, vacuum gauges, ammeters etc. Electrical equipment Wiring, piping, power leads, switches, plugs 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.

32. 6. UNECESSARY & NON URGENT ITEMS Jishu Hozen (By Ketan Kumar) 32 LEAKAGE OF CUTTING OIL UNWANTED AIR PIPE PARTS AFTER INSPECTION

33. 7. UNSAFE PLACES Jishu Hozen (By Ketan Kumar) 33 Abnormality Examples Floors 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 machinery Displaced, fallen oil or broken covers, not safe for emergency, missing emergency stop devices Lifting Devices Wires, hooks, brakes and other parts of cranes and hoists etc. Others Special substances, solvents, toxic gases, insulating materials, danger signs, protective clothing etc.

34. 7. UNSFAE PLACES Jishu Hozen (By Ketan Kumar) 34 OPEN UNGUARDED UNGUARDED

35. STEPS OF AM Jishu Hozen (By Ketan Kumar) 35 STEP -0 Preparation of Employees Team Formation Arrange Resource for Cleaning STEP -1 Initial cleanup of machines Identify 7 types of abnormalities & Tag it. Capture Pareto of 3 months downtime STEP -2 Take counter measures for the identified tags & Downtime either by restoration or by Kaizen STEP -3 Prepare CLIT standards for the machine Publish near the machine Train the employees for routine verification

36. STEP O- INITIAL CLEANING Jishu Hozen (By Ketan Kumar) 36 Prepare a Cleaning& Lubrication Map. Arrange tools. Arrange RED & WHITE tags. History of Failures Training on Jishu Hozen (AM) Training on 7 Types of Abnormalities.

37. STEP 1- INITIAL CLEAN UP Jishu Hozen (By Ketan Kumar) 37 Cleaning is INSPECTION. Use 5 SENSES for cleaning. Find out 7 TYPES OF ABNORMALITIES. Put tags on Abnormalities. Prepare list of UNFULFILLED BASIC CONDITIONS

38. TAGGING OF ABNORMALITIES Jishu Hozen (By Ketan Kumar) 38 A thorough cleaning will reveal countless problems and conditions that are less satisfactory. We mark it with tags. Attach tags to problems revealed by cleaning / inspecting. Fix the problems right away. Then remove the tags. For a problem that can’t be fixed immediately, draw up a clear plan to remove the tag.

39. 2 TYPES OF TAGS Jishu Hozen (By Ketan Kumar) 39 Red Tag - When abnormalities are to be rectified by maintenance. White Tag- When abnormalities are to be rectified by operators.

40. STEP 2- ELIMINATE PROBLEM SOURCES & INACCESSIBLE SOURCES Jishu Hozen (By Ketan Kumar) 40 Stop contamination at the source Reduce cleaning and lubrication time Modify equipment to make cleaning and lubrication easier Install covers and inspection windows to make checking easier

41. STEP 2- ELIMINATE PROBLEM SOURCES & INACCESSIBLE SOURCES Jishu Hozen (By Ketan Kumar) 41

42. STEP 2- ELIMINATE PROBLEM SOURCES & INACCESSIBLE SOURCES Jishu Hozen (By Ketan Kumar) 42

43. STEP 3- MEASURES AGAINST SOURCES Jishu Hozen (By Ketan Kumar) 43 C -CLEANING L -LUBRICATION I -INSPECTION T -TIGHTENING, & HANDOVER M/C TO OPERATOR

44. Jishu Hozen (By Ketan Kumar) 44

45. CLIT Jishu Hozen (By Ketan Kumar) 45

46. BENEFITS OF AM Jishu Hozen (By Ketan Kumar) 46

47. Jishu Hozen (By Ketan Kumar) 47

48. Jishu Hozen (By Ketan Kumar) 48 Follow us on YouTube : Raavinnovate