TPM-QM-Training Material as Per JIPM Methodology

QM Pillar Training

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:
Takemeasuresbeforehand
© 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 relationshipbetween quality
characteristicsandmaterialandenergy
condition/equipmentprecision/method
conditions
Maintenance and
management ability training
(Abilitytofindcausesystem
troublesandtoquicklyand
correctlytakeactions)
Setconditionsofequipmentnottogenerate
defects
Managementofconditionsnottogenerate
defects
(Hinshitsu –Hozen)
Zeroqualitydefects
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
•Understandingqualitydefectphenomena.
•PrepareQAMatrix.
•Set4Mconditions.
•IdentifyProcessPoint.
•ConductPMAnalyses.
•IdentifyQ-components
•PrepareQMMatrix.

5. TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
5
QM Master plan
MasterPlanforqualitymaintenanceisplanningofvarious
activitiesinthispillarwithrespecttothetimeframein
monthsandyears.AccordingtothestageofTPM
implementationitcanstartatvariouslevels.Inthe
beginningitwillstartwithdatacollectionondefectsto
improvingconditionstosustainingzerodefectconditions.

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 VsSub process
-Defect Mode VsSupport 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 defectC -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.QualityCharacteristics(FromCustomerorforcustomer).Fore.g.SmoothShiftingofgears.
2.DefectCharacteristics(Notachievement).E.g.-Shiftingnotok/ShiftingBad.
3.DefectMode(ModesofdefectCharacteristics).E.g-Shiftinghard,shiftingloose.
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
QAMatrixispreparedtoestablishtherelationshipbetween
defect/defectmodeandtheprocesswhichcausesit.It
requiresdatacollectionfordefectsatvariousprocess
stagestoprepareaQAMatrix.
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-ProcessSupport 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 FitmentNut 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
11Nut Runner Air-Pressure
Maintain Air-pressure
6 bar
Ensure
tightening
of bolt upto
last thread
Dial Gauge
with 6 bar
- -
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 JishuHozen
5. Poor Skill Horizontal Deployment PossibleYes/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 NameFunction
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
Tesnsionof
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
erDrilling
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-AUnit-B
Measurement Method DialDialDialDialDialDialDialDial
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
GaugeDial 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
MaintMaint
Produc
tion
produc
tion
produc
tion
produc
tion
produc
tion
Produc
tion
Produc
tion
Produc
tion
Produc
tion
EnggEnggEnggEnggEngg
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.