My machine camp

AUTONOMOUS MAINTENANCE ( JISHU HOZEN )

1. Imp_cell
MHL

2. (AUTONOMOUS MAINTENANCE)
•Individual preserving one’s own equipment
•Significant change from early theory of
“I Manufacture –You Repair” or “ I Make –You Fix”
•Theme is
“ If equipment changes –people will change
If people change –shop will change.”
•Operation and Maintenance are like wheels on both sides of
a car.
•I can decide, I can do, I am empowered to do.
JISHU –HOZEN
Imp_cell
MHL

3. Imp_cell
MHL

4. A.M. ELIMINATES THE BITTER
COMPLAINTS WHICH COME FROM …….
“PRODUCTION” “MAINTENANCE”
•Maintenance does not
know its job
•They take too long to fix
the equipment
•This equipment is so
antiquated, no wonder it
breaks down
•We are too busy to do
vital daily checks.
•They (Production) don’t
know how to operate
•We get lot of repairs so
we don’t have ample to do
a real corrective action
and are forced to only do
disposition
•We repair the standards,
but they don’t do the
checks
Imp_cell
MHL

5. A.Activities to prevent deterioration
By correct operation, Improvement of basic conditions and
adjustments to prevent quality defects.
B.Activities to measure deterioration
By senses (touch, see, hear, smell)
By vibration, fluid analysis etc.
C.Activities to rectify deterioration
By improving reliability, maintainability of machines (MTBF, MTTR)
ROLE OF PRODUCTION ROLE OF MAINTENANCE
•PlayvitalroleinA.Also
recordsmaintenancedatafor
preventionofrecurrencesof
problemandMPdesign
•PlayroleinBbyfivesenses
•PlayroleinCbyprompt
reportingandassistingin
sporadicfailure
•PlayroleinAasguideandeducationistand
providinghelpinidentifyingareas“sourcesof
problem”and“hardtoClean”.
•PlayroleinBbyvibration,fluidAnalysis
•PlaymajorroleinCbyimprovingMTBF,
MTTR
•BesidesthattheymaintainMIS,workfornew
equipmentdesignandsetupmaintenance
standards
CLASSIFICATION OF MAINTENANCE ACTIVITIES
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MHL

6. 0.PREPARATION STAGE ( 1 ‘S’, 2 ‘S’ & TRAINING )
1.INITIAL CLEANING & INSPECTION
2.COUNTER MEASURE AGAINST SOURCE OF
CONTAMINATION AND HARD TO ACCESS AREA
3.CREATION OF TENTATIVE STANDARDS
4.GENERAL INSPECTION & SKILL DEVELOPMENT
5.AUTONOMOUS INSPECTION
6.STANDARDISATION
7.CONSISTENT AUTONOMOUS MANAGEMENT
SEVEN STEPS OF JISHU HOZEN
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MHL

7. STEP 1
CLEAN & INSPECT

8. Imp_cell
MHL

9. ELIMINATE PROBLEM SOURCE
AND HARD TO ACCESS AREA
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MHL
STEP 2

10. Imp_cell
MHL

11. Imp_cell
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12. Modify Equipment to make Cleaning Easier
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MHL

13. Imp_cell
MHL

14. ESTABLISHING TENTATIVE
STANDARDS FOR JISHU -HOZEN
( CLEANING & LUBRICATION)
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MHL
STEP 3

15. Imp_cell
MHL

16. Model Equipment Selection Standards
CategoryNo. Item Evalua
tion
Score
Evaluation guide
Productio
n aspect
(PD)
1Average level of operation42180% or greater: 4
60% or less: 1
2Presence of a spare or
alternative machine, and
the ease of switching over
to that machine
421None, or requires a larges amount
of time to switch over: 4
Present, & easy to switch over: 1
3Effect that a failure has on
other equipment
421Effects a large amount of
equipment inside the plant: 4
Has nearly no effect on other
equipment:1
4Failure frequency (MTBF)4214 times a month or greater:4 1
time per day or less:1
5Downtime for repairing
failure (MTTR)
421Avg. of one time/day or greater : 4
Avg. of one time/Hr. or fewer : 1
Quality (Q)6Effect on product quality
assurance
421Large effect : 4
Almost No effect : 1
7Amount lost from average
drop in quality per failure
incident
421Rs. 25,000/-or greater : 4
Rs. 2,500/-or greater : 1
Imp_cell
MHL

17. Model Equipment Selection Standards –Contd.
CategoryNo. Item Evalua
tion
Score
Evaluation guide
Cost ( C )8Amount lost in energy,
material and labour
expenses due to failure
421Rs. 25,000/-or greater : 4
Rs. 2,500/-or greater : 1
9Extent of overall repair
cost
421Monthly avg. of Rs. 25,000/ or
greater : 4
Monthly avg. of Rs. 2,500/ or
less : 4
Safety ( S
)
10Risk that failure will cause
injury or illness
421Quite large risk : 4
Virtually no risk : 1
11Risk that failure will cause
pollution
421Quite large risk : 4
Virtually no risk : 1
General Evaluation Grade : A B C
Use the points in the score column for evaluation, and use no other pints
General evaluation standard 26 points or greater : Rank A (greater than 60% of
maximum)
18 points or greater : Rank B (40-60% of maximum)
17 points or less : Rank C (Under 40% of maximum)
The model machine selected should be an “A” rank machine, and should have a
sufficient level of explicability in other machines.
Imp_cell
MHL