Jishu hozen

JISHU HOZEN is TPM pillar, Not complete slides

1. Eight Steps in JISHU HOZEN 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% 1. Prep of Employees 2. Initial Cleanup of Machine 3. Take Counter Measures 4. Fix Tentative JH Stds 5. General Inspection 6. Autonomous Inspection 7. Standardization 8. Autonomous Management Prep by Tanveer Ahmed, BE,ME Textile, MS/ Mphil Quality Managements (Industrial Management) 1

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

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

4. JISHU- HOZEN 4. Setup & Adjustment Loss 6. Defect Quality Loss 5. Yield Loss WHY Autonomous Maintenance 7. Poor Skills of Operator 3. Breakdown Loss 1. Minor Stoppage Loss 2. Reduced Speed Loss 8. Improper Position to Conduct Inspections Preventive Maintenance Production Maintenance TPM American Style of PM Japan Style of PM Maintenance Departments Sole Responsibility 9. Confirmation of working conditions 10. Daily Inspection / Periodical Inspection 10. Activities to prevent eqpt degradation 11. Activities to keep record on eqpt degradation 12. Keep cleaning, Inspection, Additional light 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 5. To eliminate equipment failure 6. To eliminate quality defect 2. To make operator familiar with his equipment 7. To eliminate cost losses 1 To establish basic equipment condition 3. To prevent equipment deterioration 4. To maintain in optimal condition Prep by Tanveer Ahmed, BE,ME Textile, MS/ Mphil Quality Managements (Industrial Management) 5

6. JISHU- HOZEN 1. Indl preserving one’s own eqpt The Mind Set 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 We get lot of repairs so we don’t have ample to do a Real corrective and are forced to do only temporary job This eqpt is so OLD no wonder it breaks down again & again We are too busy to do vital daily checks We Prep the stds but they do not do the checks Prep by Tanveer Ahmed, BE,ME Textile, 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 Prep by Tanveer Ahmed, BE,ME Textile, MS/ Mphil Quality Managements (Industrial Management) 7

8. JISHU- HOZEN Three Key Tools for Autonomous Maintenance People Activity & Findings Treasures Team & Team Mission Step1- initial 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 2- Source 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. JISHU- HOZEN Three Key Tools for Autonomous Maintenance Dept / Line: Bldg Y Area: Bag Printer Mach ID Date: 4/28 /14 Tag Diagram No. Items Criteria Method Tools T(Min) Freq Person Resp Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management) 9

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

11. JISHU- HOZEN Equipment Deterioration ACCELERATED Deterioration (Eliminate Cause) Natural Deterioration (Extend Life Time) 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 C. Activities to Rectify deterioration By improving reliability, maintainability of machines (MTBF, MTTR) 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) 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 1. Prep a Cleaning & Lubrication Map Initial Preparation . Prep of JH Activities 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 2. Use 5 Senses for Cleaning Initial Cleaning 1. Cleaning is Inspection 3. Find out 7 Types of Abnormalities 4. Put Tags on Abnormalities 5. Make the List of Hard to Clean Hard to Lubricate Hard to Tighten Hard to Inspect Hard to Adjust Record cleaning time Carryout Audit on 1 st 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. Places In Accessible Unsafe 2. Sources Contamination Quality Defect 1. Items Un-necessary – Non Urgent 1. Minor Flaws 1. Unfulfilled Basic Conditions Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management) 15

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

17. JISHU- HOZEN STEP - 1 Initial Cleaning – 7 Types of Abnormalities 2.Unfulfilled Basic Conditions Lubrication Lubrication Supply Dirty, Insufficient, Unidentified, Unsuitable, Leaking Oil Level Gauges Tightening Dirty, Damaged or deformed lubricant inlets, faulty lubricant pipes 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 Cleaning Checking Adjustment Operation Position of Pressure Gauge, Thermometers, Flow Meters, Moisture Gauges, Vacuum Gauges etc. Machine Construction, Covers, Layout, Footholds, Space Lubricating Tightening 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 Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management) 18

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

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

21. JISHU- HOZEN STEP - 1 Initial Cleaning – 7 Types of Abnormalities 6. Quality Defect Sources Foreign Matter Shock Viscosity Concentration Inadequate Warming, Heating, Compounding, Mixing, Evaporating, Stirring etc. Dust, Rust, Powder, chips, Moisture, Wire scraps, Wood Pieces, Paper pieces, stones etc. Moisture Gain Size Dropping, Jolting, Collision, Vibration etc. Too little or Too Much, Infiltration Abnormalities in Screens, Compressed air separators, Centrifugal Separators Inadequate Warming, Heating, Compounding, Mixing, Evaporating, Stirring etc. Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management) 21

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