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5th TPM National Conference

Session B : Jishu Hozen (Autonomous Maintenance)

Topic :
JH Step 1-4

Presentation by

Mr J P Garyali Sr General Manager Shriram Pistons & Rings Ltd

Shriram Pistons & Rings Ltd

JH Step 1-4

TPM CLUB ANNUAL CONFERENCE NEW DELHI

SLIDE NO. 1

PRESENTATION ON AUTONOMOUS MAINTENANCE (JISHU HOZEN) STEP 1 TO STEP - 4

BY : J.P.GARYALI
SHRIRAM PISTONS & RINGS LTD. GHAZIABAD
DATE : 1ST MARCH 2005

OUTLINE OF THE COMPANY

SLIDE NO. 2

OUTLINE OF THE COMPANY

SHRIRAM PISTONS & RINGS LTD.

5th TPM National Conference

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Shriram Pistons & Rings Ltd

JH Step 1-4

OUTLINE OF THE COMPANY

1. OUTLINE OF THE COMPANY


INCORPORATED IN 1972
TURNOVER IN LAST F.Y.

Rs.310 Crores

TURNOVER IN F.Y. 2005 (PLAN)

Rs.350 Crores

OUTLINE OF THE COMPANY

SLIDE NO. 4

MAIN COMPANY DETAILS


TOTAL EMPLOYEES
OFFICERS STAFF WORKMEN 284 230 2476

2990

TOTAL AREA

ELECTRIC POWER

TOTAL NO.OF MACHINE

105,000 SQ.M (26 Acres)

GOVT. 7000 KVA OWN: 12000 KVA

830

5th TPM National Conference

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Shriram Pistons & Rings Ltd

JH Step 1-4

OUTLINE OF THE COMPANY

SLIDE NO. 5

PRODUCTS
PISTONS RINGS

PINS

ENGINE VALVES

OUTLINE OF THE COMPANY

SLIDE NO. 6

FOREIGN COLLABORATIONS
FOR PISTONS FOR PISTONS

HF
KOLBENSHMIDT- GERMANY (Collaboration since 1972) HONDA FOUNDRY- JAPAN (Collaboration since 1989)

FOR RINGS

FOR ENGINE VALVES

RIKEN RIKEN
RIKEN CORPORATION- JAPAN (Collaboration since 1978) FUJI- OOZX- JAPAN (Collaboration since 1993)

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Shriram Pistons & Rings Ltd

JH Step 1-4

OUTLINE OF THE COMPANY

SLIDE NO. 7

JOURNEY TOWARDS EXCELLENCE

CHALLENGE TPM SPECIAL AWARD - 2007


TPM EXCELLENCE AWARD YEAR 2004 TS 16949 YEAR 2003 OHSAS 18001 YEAR 2003 ISO 14001 YEAR 2001 QS 9000 YEAR 1999 ISO 9001 YEAR 1994

TPM IMPLEMENTATION

SLIDE NO. 8

TPM IMPLEMENTATION

SHRIRAM PISTONS & RINGS LTD.

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Shriram Pistons & Rings Ltd

JH Step 1-4

TPM IMPLEMENTATION

SLIDE NO. 9

12. DATE OF TPM INAUGURATION


TPM was introduced at SPRL in JANUARY 2000

TPM IMPLEMENTATION

SLIDE NO. 10

3. T P M POLICY

ZERO FAILURE, ZERO DEFECT & ZERO ACCIDENT THROUGH INTRODUCTION OF T P M, WITH PARTICIPATION OF ALL EMPLOYEES.
MAXIMUM PROFITS THROUGH IMPROVEMENT OF OVERALL EQUIPMENT EFFICIENCY, REDUCTION IN COST AND INCREASE IN CUSTOMER SATISFACTION

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Shriram Pistons & Rings Ltd

JH Step 1-4

TPM IMPLEMENTATION

SLIDE NO. 11

2. TPM PROMOTION ORGANIZATION


Executive Director TPM Steering Committee SUBCOMMITTEES
TPM TPM Secretariat

1. Kobetsu Kaizen 2. 3. 4. 5. 6. 7. 8. Autonomous Maintenance Planned Maintenance Quality Maintenance Initial Control Education & Training Office TPM Safety, Health & Envimt
HOD H OD Of f icer S
W W W W

Secretariat

MANUFACTURING
HOD H OD Of f icer S
W W W

PLANTS &

DEPTTS.
HHOD OD

HOD
HOD Of f icer Of f icer S
W W W W

H
Of f icer Of f icer S
W W W W

Of f icer S S
W W W

Of f icer S
W W

Of f icer S S
W W W

S
W W

S
W W

S
W W

S
W W

S
W W

HOD H OD Of f icer S
W W W

HOD H OD Of f icer Of f icer S


W W W W

HOD H OD Of f icer Of f icer S


W W W W

HOD H OD Of f icer Of f icer S


W W W W

Of f icer S S
W W W

S
W W

S
W W

S
W W

S
W W

S
W W

S
W W

S
W

Plant TPM Promotion Committee (10 Nos.)

Area TPM Promotion Committee (66 Nos.)

Circles (242 Nos.)

TPM IMPLEMENTATION

SLIDE NO. 12

5. T P M IMPLEMENTATION PROCESS
CONSULTANT AUDIT / GUIDANCE TPM TRAININGS SEMINARS

MODEL MACHINE ACTIVITY

TPM KICK- OFF SMALL GROUP ACTIVITIES

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Shriram Pistons & Rings Ltd

JH Step 1-4

JISHU HOZEN ACTIVITY

SLIDE NO. 13

IMPLEMENTATION OF AUTONOMOUS MAINTENANCE STEP 1 TO STEP - 4

SHRIRAM PISTONS & RINGS LTD.

JISHU HOZEN ACTIVITY

SLIDE NO. 14

PHILOSOPHY BEHIND AUTONOMOUS MAINTENANCE


A workman who is operating a machine or equipment, day in & day out, is expected to have the best knowledge about the machine, operation.

If a, little knowledge & training is given to this operator on simple maintenance areas, it is possible for him to broaden his expertise towards the maintenance of this machine as well.

(Contd.)

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Shriram Pistons & Rings Ltd

JH Step 1-4

JISHU HOZEN ACTIVITY

SLIDE NO. 15

With each operator, becoming partly a maintenance man also , for his machine, results in, huge benefits as given below : ! Enormous reductions in machine breakdowns & stoppages, through regular inspection & early defect warnings. ! Drastic improvement in the life of the machines, components through controlling the forced deterioration areas, an each machine. ! Prevention of leakage of oils/coolants/Air etc.. !Marked improvement in the availability of the machine for production.

JISHU HOZEN ACTIVITY

SLIDE NO. 16

PREPARATION (STEP 0)
This is the most important step in the successful implementation of the Autonomous maintenance in on organization. This comprises of following sub activities.:

1. Making of a plan :
! This includes formation of circles, company wide and allocating the various machines to each circle. (to create the ownership concept.) ! Making of inspection formats for Auditing at the end of each Step activities. ! Making a schedule of the activities to be undertaken under each step. (Contd.)

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Shriram Pistons & Rings Ltd

JH Step 1-4

JISHU HOZEN ACTIVITY

SLIDE NO. 17

2. Imparting Trainings ! Regarding the basic working of the machine and the accessories/ Sub assemblies. !Training on safety (Both electrical & Mechanical) ! Understanding the conditions of forced deterioration & losses. 3. Training on the skills of : ! Cleaning : Method, correct tools for cleaning (specific to a machine) ! Lubrication : Purpose, Type, Method quantity, Period etc.

! Retightening : Purpose, correct fastening methods, use of correct tools etc.

JISHU HOZEN ACTIVITY

SLIDE NO. 18

Check points are developed to help the operator recognize the abnormalities CHECKPOINTS FOR NUTS AND BOLTS
Slight Defects Are any nuts or Bolts loose ? Are any nuts or Bolts missing ?

Bolts Lengths

Do all Bolts protrude from nuts by 2 3 thread lengths ? Are Flat washers used on long holes ? Are tapered washers used on angle bars and channel ? Are spring washers used where parts are subject to vibration ? Are identical washers used on identical parts ? Are bolts inserted from below. and are nut visible from the outside ? Are devices such as limit switches secured by at least to bolts ? Are wing nuts on the right way around ?

Washers

Attachment of Nuts & Bolts

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Shriram Pistons & Rings Ltd

JH Step 1-4

JISHU HOZEN ACTIVITY

SLIDE NO. 19

SIMILARLY CHECK POINTS ARE DEVELOPED FOR OTHER PARAMETERS FOR EXAMPLE :
! Check Points for Lubrication ! Check Points for Transmission System ! Check Points for Hydraulic ! Check Points for Pneumatics ! Check Points for Electrical ! Check Points for General Purpose Equipment

JISHU HOZEN ACTIVITY

SLIDE NO. 20

BASIC APPROACH
7 6 5 4 3 2 1 Autonomous Management. Standardization Autonomous Inspection General Inspection Tentative Standards Contamination Sources Initial Cleaning

Implementation of each step.

Through Participation of all Employees.

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Shriram Pistons & Rings Ltd

JH Step 1-4

JISHU HOZEN ACTIVITY

SLIDE NO. 21

CHARACTERISTICS
Significant learning From Manager Model M/cs. Activity board for promotion of J.H. Activity.

(Improved 5S) Designated place for tooling & WIP.

Participation of all employees.

JISHU HOZEN ACTIVITY

SLIDE NO. 22

JISHU HOZEN ACTIVITY - MASTER PLAN


PREPARATION PERIOD OCT-99 ~MAY-01 INTRODUCTION PERIOD JUNE-01~MAR-03 IMPLEMENTATION PERIOD APR-03~DEC-03
APR- 03 SEP- 03 OCT- 03 MAR- 04

YEAR ITEM PLAN OF ACTIVITY

ESTABLISHMENT PERIOD JAN-04~MAR-06


APR- 04 MAR- 05 APR- 05 MAR- 06

OCT- 99 APR- 00 OCT- 00 APR- 01 OCT- 01 APR- 02 OCT- 02 MAR- 00 SEP- 00 MAR- 01 SEP- 01 MAR- 02 SEP- 02 MAR- 03

STEP 0

STEP 1 - 3

STEP 4

STEP 5 - 6
CHALLANGE TPM EXCELLANCE AWARD

MODEL MACHINE STEP-1 (9 MACHINES) 1ST LEVEL MACHINES (53 MACHINES)


KICK OFF - JAN 2000

STEP-2 STEP-3 STEP-1 STEP-2 STEP-3 STEP-1 STEP-2 STEP-3


STEP - 4 STEP - 4 STEP - 4

2ND LEVEL MACHINES (768 MACHINES)

PLAN

COMPLETED

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Shriram Pistons & Rings Ltd

JH Step 1-4

JISHU HOZEN ACTIVITY

SLIDE NO. 23

GOALS

TARGET SETTING

To develop operators ability to MAINTAIN and OPERATE, their own equipment / machines, EFFECTIVELY.

OBJECTIVES
To reduce minor stoppages during machines operation.
100

Th.nos Th.Nos /MONT /Month H

100 75 75 50 50 25 25 0 0

64 64

Minor stoppages (All Plants) (Th.Nos/Month) Minor stoppages


(Th.Nos./Month)
11 21

GOOD GOOD

2000* (Bench Mark)

2004 (Target)

* Data recording started from Year 2000

To reduce cleaning / inspection / lubrication time.


900 750 600 450 300 150 0

Hours/Day

Time reduction trend (All Plants)


622

(Hours/Day)

C LE A N I N G IN S P E C T I O N LUB R IC A T IO N

183 72

200 60 24
2

GOOD

2000* (Bench Mark)


1

2004 (Target)

* Data recording started from Year 2000

JISHU HOZEN ACTIVITY

SLIDE NO. 24

STEP 1 INITIAL CLEANING


! Cleaning is required to UNCOVER or DISCOVER, the Leaks, lossness, Damage, and any other deteriorated condition of parts on the machine. ! one may be able to identify 200 to 500 defects on machines which are revealed during cleaning : !The defects are categorized & identified as : 1. 2. White Tags : (Defects which can be corrected by the operator/circle members themselves) Red Tags : (Defects which require the assistance of Maintenance personnel for correction.) ! For Deciding the correctness & ownership of Red tags a regular meeting is held between the circle members & the maintenance personnel.

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JH Step 1-4

JISHU HOZEN ACTIVITY

SLIDE NO. 25

JISHU HOZEN ACTIVITY

SLIDE NO. 26

BACKGROUND
OIL LEAKAGES & COOLANT SPLASH SCATTERED CHIPS

JUMBLED WIRES

DUST & DIRT ON M/CS

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Shriram Pistons & Rings Ltd

JH Step 1-4

JISHU HOZEN ACTIVITY

SLIDE NO. 27

ACTIVITIES UNDER STEP 1 (INITIAL CLEANING) FLOW CHART


Circle Leader + Circle Members M/c Allocated : (Boring M/c No. 11) e.g. Cleaning for Inspection & Identify Defects Put Defect Tags (White Tags or Red Tags) Make Matrix of all tags Category wise Meeting for allocation of tags

White Tags
Assign Responsibility to the Circle Members with TDC

Red Tags
Assign Responsibility to Maint. Personnel with TDC

Generate Counter measures

Generate Kaizens

Generate One Point lesson

Consolidate the Results as Cumulative Trend Graph

(Next Page)

JISHU HOZEN ACTIVITY

SLIDE NO. 28

ACTIVITIES UNDER STEP 1 (INITIAL CLEANING)

(Contd.)

TREND GRAPH

No. of Defects

No. of Kaizen

No. of Breakdown

Minor Stoppage

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Shriram Pistons & Rings Ltd

JH Step 1-4

JISHU HOZEN ACTIVITY

SLIDE NO. 29

Circle members performing initial cleaning.

FUGUAIS

JISHU HOZEN ACTIVITY

SLIDE NO. 30

ACTIVITIES UNDER STEP 2


Eliminate/ reduce :

FLOW CHART
IDENTIFY

! sources of forced deterioration ! Hard to Access Areas.


Circle Leader + Circle Members M/c Allocated : Boring M/c No. 11

IDENTIFY
conditions of hard to access areas in and around the machine

Conditions of Forced deterioration In coolant,chips,slides,moving parts Hydraulic etc.

Take up kaizens themes for Improvement Kaizen Implementation By Circles/ Teams themselves.

Develop One Point Lessons Kaizen Implementation By Circle/ Teams with Assistance from PM

Consolidate & Monitor the results as Trend Graphs.

No. of kaizens

No. of OPL

No.of defects Found & Closed

No.of Breakdown

No.of Minor Stoppages

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Shriram Pistons & Rings Ltd

JH Step 1-4

JISHU HOZEN ACTIVITY

SLIDE NO. 31

2000 1800 1600 1400

Elimination of Sources of contamination - Status


(Numbers)
1378 1462 1462 1462 1462 1462 1462 1243 792 497 568 478 675 607 401 708

IDENTIFIED RECTIFIED

NUMBERS

1200 1000 800 600 400 200 0 84 49


Apr 00

GOOD

123

142

202 149
Jan 01

284 186
Apr 01

329 248
Jul 01

428

332
Oct 01

101 116
Jul 00 Oct 00

Jan 02

Apr 02

Jul 02

Oct 02

Jan 03

Apr 03

Jul 03

Oct 03

MONTHS

Elimination of Source of contamination Before

Localized guard

No coolant splashing around the M/c.

No Guard

After

Prevent coolant splashing

JISHU HOZEN ACTIVITY

SLIDE NO. 32

4400 4000 3600 3200 2800 2400 2000 1600 1200 800 400 0 265

Simplification of hard to access areas - Status


(Numbers)
3492 3320 3742 3742 2518 2264 2380 1764 1124 1297 1463 1983 3742

IDENTIFIED
3742

RECTIFIED

NUMBERS

1124 458 698 871 542 Oct 00 Jan 01

1236

1410

1649

1852

2015

GOOD

1076

197 362 Apr 00 Jul 00

Apr 01

Jul 01

Oct 01

Jan 02

Apr 02

Jul 02

Oct 02

Jan 03

Apr 03

Jul 03

Oct 03

MONTHS

Improper hose pipe

Proper hose pipe

Before

After

Relayout Of Hose pipes

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Shriram Pistons & Rings Ltd

JH Step 1-4

JISHU HOZEN ACTIVITY

SLIDE NO. 33

ACTIVITIES UNDER STEP 3 MAKING OF TENTATIVE STANDARDS


After having completed Step 1 & Step 2 activities the operator has now, fairly good level of knowledge and he can now set Tentative Standards for : ! Inspection ! Lubrication ! Cleaning

Based on the above activities he can also fix the standards of time, required for each activity. After having developed the above standards, the operator may now implement these on his machine and observe the results, for at least 3 months. All the machines in the plant should now reach the Step 3 level. (Contd.)

JISHU HOZEN ACTIVITY

SLIDE NO. 34

STEP 3 FLOW CHART


Circle Leader + Circle Members M/c Allocated : Boring M/c No. 11 Develop Tentative Standards for 1. Inspection 2. Lubrication 3. Cleaning Implementation for 3 Months

Paint the Machines now with a standard new colour. At the end of Step 3 all the Machines look Completely upgraded & wear a new look. Next improve the surroundings of all the machines

Now a complete change of shop floor takes place.

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Shriram Pistons & Rings Ltd

JH Step 1-4

JISHU HOZEN ACTIVITY

SLIDE NO. 35

ACTIVITIES UNDER STEP 3


Preparation of tentative standard for cleaning, lubrication & inspection. Tentative Standard Check Sheet

Route Map

JISHU HOZEN ACTIVITY

SLIDE NO. 36

VISUALIZATION ON MACHINES

Marking on Pressure Gauges

Marking Oil Level

Arrow to indicate Direction of belt rotation

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JH Step 1-4

JISHU HOZEN ACTIVITY


75000 60000 45000 30000 15000 0
8654 14162 11467 6231 Jan 00 Apr 00 Jul 00 46270 39186 31886 2877730474 26645 2442625662 36582 29590 27221 25358 23494 2131822283 48010 48694 48694 48694 48694

SLIDE NO. 37

Defects trend (Upto step 3)


(Numbers)

FOUND CLOSED

Numbers

46843 44389

GOOD

22072 1918220718 15528 18620 16723

Oct 00

Jan 01

Apr 01

Jul 01

Oct 01

Jan 02

Apr 02

Jul 02

Oct 02

Jan 03

Apr 03

Jul 03

Oct 03

MONTHS

50000 50000

Defects classification (Upto step 3) Fuguai classification


(Numbers) (Numbers)

48694 48694 48694 48694

(N U M B ER Numbe rs S).

40000 40000 30000 30000 20000 20000 10000 10000 0 0


12661 12661 12661 12661 16436 16436 16436 16436 4802 3828 4802 3828 3828 4802 4802 3828
Unf ulf illed basic Unfulfilled condit t io ns basic condittions Inaccessib le Places Inaccessible Places ont aminat ion sources Contamination sources

5036 3755 2176 5036 3755 5036 3755 2176 2176 2176 5036 3755
Source of qualit y Source of def ect d quality Unnecessary it ems Unnecessary items unsaf e places Tot al

M inor Flaws

Minor Flaws

unsafe places

Total

(AS ON 30.6.04)

defectd

JISHU HOZEN ACTIVITY

SLIDE NO. 38

ACTIVITIES UNDER STEP 4 (GENERAL INSPECTION)


In Step 4, thorough knowledge and Training is given to the operators, to upgrade their knowledge and Maintenance skill. With the assistance of In house teams of experts and maintenance heads, various basic course modules are developed on different topics such as : ! Nut & Bolts ! Lubrication !Hydraulic !Pneumatic !Drive !Electric !Safety !Machining Condition
(Contd.)

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JH Step 1-4

JISHU HOZEN ACTIVITY

SLIDE NO. 39

After these modules are developed, these are reviewed by a common core committee & then finalized for issue & Training.

A structured Programme for imparting this knowledge & Training to all the employees, is drawn out & training implemented. At the end of Step 4, there is a radical improvement in the attitude of the operators, due to enhanced knowledge and skill levels.

(Contd.)

JISHU HOZEN ACTIVITY

SLIDE NO. 40

STEP 4 FLOW CHART


Develop 8 Technical Modules Imparting Training on 8 Tech modules to all employee Reexamine the machines & Equipment with higher knowledge & skill achieved under Step - 4 Now find more defects on the machines. Updating the standards (Developed in Step 3)

Implement the new standards for 3 months

Consolidate & monitor the progress through following parameter

No. of New kaizens

No. of new defects

No. of new One Point Lesson

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Shriram Pistons & Rings Ltd

JH Step 1-4

JISHU HOZEN ACTIVITY

SLIDE NO. 41

Training modules preparation and implementation

Cut models

Class room training

JISHU HOZEN ACTIVITY

SLIDE NO. 42

Example of General Inspection.


Inspection on Belt Inspection on Coupling

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JH Step 1-4

JISHU HOZEN ACTIVITY

SLIDE NO. 43

16000 14000 12000

Trend of new Defects (in step 4)


(Numbers) 11483 10080 12277 12329 10451 9529 7571 12382 12431 13248 13292 13323

FOUND CLOSED

GOOD

10000 NUMBERS 8000 6000 4000 2000 0 Jun' 03 Sep' 03 Dec' 03 1803 175

Mar' 04

Jun' 04

Sep' 04

Dec' 04

JISHU HOZEN ACTIVITY

SLIDE NO. 44

10000 9000 8000 7000 6000


NUMBERS

Status of defects classification under step 4


8933 8563
(Number of defects)
FOUND - 13323 CLOSED - 12431

5000 4000 3000 2000 1000 0


4.2 4.1 4.3 4.4 Nut & Bolts Lubrication Hydraulic Pneumatic 4.5 Drives 4.6 Electrical 4.7 Safety

1199 959

1023 913

480 399

627 581

883 851 104 100 74 65


4.8 Machining Condition

(AS ON 31.12.04)

Defects

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JH Step 1-4

JISHU HOZEN ACTIVITY

SLIDE NO. 45

STEP WISE STATUS OF ALL CIRCLES


STEP WISE STATUS OF ALL CIRCLES
PLANT ALL CIRCLES STEP-1 STEP-2 STEP-3 STEP - 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8

AL.FDY. PISTON PLANT RING FDY. RING PLANT PIN PLANT E.V.FORGE E.V.M/C TOOL ROOM PAW (AS ON 30.6.04)

23 55 25 49 18 18 32 10 12

Completed

CHAPTER-5 JISHU HOZEN ACTIVITY

SLIDE NO. 46

6.
9000 8000 7000 6000 N U M BERS 5000 4000 3000 2000 1000 0
Jan Apr Jul 00 00 00

KAIZEN TREND - OVERALL


(Number of Kaizens) (upto step-4)
6695 5941 4905 3657 6989

7318 7426

7516 7667

7714

GOOD

486

889

1251

1648

2015

2411

2680

2951 3149

3358

Oct Jan Apr Jul Oct 00 01 01 01 01

Jan Apr Jul Oct 02 02 02 02

Jan Apr Jul 03 03 03

Oct Jan Apr Jul 03 04 04 04

Oct' 04

MONTHS

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Shriram Pistons & Rings Ltd

JH Step 1-4

JISHU HOZEN ACTIVITY

SLIDE NO. 47

Example - Elimination of Minor Stoppages


TPM/STD/12 REVISION NO.-00

Activity Result Area

KK P

JH

QM PM SHE OTPM IC Q C D S

ET M

KAIZEN SHEET
Plant: PISTON PLANT

Machine Name: PRE OVAL TURNING


small dia pistons Bench mark Target Kaizen start Kaizen finish

Machine No: 110

Kaizen theme: Elimination of Minor Stoppage. Phenomna : Frequent adjustment required in the length of rocker arm

Idea: Modified the length of rocker arm to accomadate.

Problem/present status:

Countermeasure:

360 NOS. ZERO NOV' 03 DEC' 03 MR.PRADEEP SRIVASTWA MR.BABLI MR.MAHIPAL

(words / sketch)

(words / sketch)

Team members: MR.VIKASH KUMAR

Benefits:
PRODUCTIVITY INCREASED BY 4 % IN SOME

Analysis:
Minor stoppage occur 4- 5 times in a shift. Totaling time (360 nos/Month)
Why

Results:
Minor stoppage reduced.
Nos / Month

PISTON MODEL.

Pressure on rocker arm disturbed.


Why

360

Spacer used in rocker arm assembly in some small dia models.


Why

0
Before After

Scope & Plan for Horizontal Deployment S.No. Machine TDC Responsibility No. -

Status -

Inedequate length of rocker arm.

JISHU HOZEN ACTIVITY

SLIDE NO. 48

ONE POINT LESSON TREND - OVERALL


4500 4000 3500 3000 2500 2000 1500 1000 500 0 Jan Apr 00 00 Jul 00 Oct Jan Apr 00 01 01 Jul Oct 01 01 Jan 02 Apr 02 Jul Oct 02 02 Jan 03 Apr 03 Jul 03 Oct Jan 03 04 361 109 226 617 1280 1108 1209 933 1015 741 836 1843

(Number of one point lesson) (Upto Step - 4)


2830 2354

3638

3996 4123

4362

NUMBERS

GOOD

Dec 04

MONTHS

3600 3200 2800

(Category wise One point lessons)


(Upto Step - 4)
2911 2201 1768 1306 546 623 168 45
Apr 01

3131 3218

3379

BASIC KNOWLEDGE IMPROVEMENT CASES TROUBLE CASES

NU M BERS

2400 2000 1600 1200 800 400 0 100 2 7 6


Jan 00

198 22
Apr 00

279 18
Jul 00

468

713 171 49
Jul 01

792 172 51
Oct 01

872 175 61
Jan 02

967

1008 354 375 442 285


Jul 03

GOOD
540 325
Oct 03

569 336
Jan 04

613 370
Dec 04

157 64 118 38 31
Oct 00 Jan 01

177 64
Apr 02

182 90
Jul 02

209 139
Oct 02

230 254
Jan 03 Apr 03

MONTHS

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JH Step 1-4

JISHU HOZEN ACTIVITY

SLIDE NO. 49

TANGIBLE RESULT
100

RESULTS
Minor stoppages Minor stoppages
(Th. Nos./Month) (Nos./Month)

Th. Nos./MONTH NOS./MONTH

75

64

56 49 46 39 33 23 20

77 % Reduction
18

GOOD

50

25

17 15 11

2000 2000 (Benchmark) Benchmark


700 600

Oct' 02

Jan' 03

Apr' 03

Jul' 03

Oct' 03

Jan' 04

Apr'04

Jul'04

Oct'04

Dec'04

2004 (Target)

Time reduction trend


622

CLEANING INSPECTION LUBRICATION

Hours/Day

(Hours/Day) (As on 31.12.04)


388

500 400 300 200 100 0 183 94 72 35


1ST PHASE

234 195 72 29
2ND PHASE

GOOD
64 31
3RD PHASE

2000 (Benchmark)

CHAPTER-6 PLANNED MAINTENANCE ACTIVITY

SLIDE NO. 50

TPM REPORT PAGE NO. 114

RESULTS
" Breakdown Frequency - Trend
1000

BREAKDOWN NUMBERS / MONTH

Breakdown Frequency - Trend


720 648 475 380

800 600 400

75 % Reduction 77 % Reduction

GOOD

218 200 0

183 167 100

1999 (Bench Mark)

2000

2001

2002
PERIOD

2003

2004 (Jun 04)

2004 (Nov 04)

2004 (Target)

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JH Step 1-4

JISHU HOZEN ACTIVITY

SLIDE NO. 51

INTANGIBLE RESULTS
Neat and clean shop floor

Active participation / Team work

Improvement in operators Attitude

END OF PRESENTATION

5th TPM National Conference

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