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Safety, Health &

environment

Education & Training

Tool Maintenance

Office TPM

Quality Maintenance

Planned Maintenance

Focussed Improvement

Autonomous Maintenance

Initial flow Control

6
9

Jishu Hozen autonomous Maintenance

Purpose :
1. Training of operators to be proficient in equipment
2. Protecting ones own equipment

Members:

1. Operators
2. Line leaders
3. supervisors

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JISHU HOZEN
Jishu Hozen is the activities which
each operator performs -daily inspection ,
lubrication, parts replacement, repair,
trouble-shooting, accuracy checks and
so forth on his own equipment, aiming at
achieving the goal of keeping ones own
equipment in good condition by one self
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Jishu Hozen 7 Steps

7. Autonomous
Management
6. standardisation
5. Autonomous Inspection

4. General Inspection
3. Tentative standards

2. Counter Measures
1. Initial Clean up
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Jishu - Hozen
Steps for developing
1. Initial
Cleaning
(inspection)

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All- around clean-up of

dust and dirt on equipment.
Oiling and re-tightening of
bolts and nuts
Finding and restoration of
Fuguai (abnormalities)

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Purpose of cleaning

So Cleaning isESSENTIAL

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DIS- COVER

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----

DISCOVER

WHAT TO CHECK

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Loose bolts & nuts.

Loose wires.
Missing parts.
Rusted parts.
Broken parts.
Cracked parts.
Air leaks
Oil leaks
Coolant leaks.
Dirt, dust and cobwebs.
Oil on the floor.
Scrap around the machine.
Burr and swarf around the machine.
Abnormal heat.
Abnormal sound.
Abnormal vibration.

Jishu Hozen 7 Steps

Step 1: Initial Clean up
a.
b.
c.
d.

e.
f.
g.
h.
i.
j.
k.
l.

Formation of JH circles
division of machine pars to operators
Training on abnormality identification
Preparation of red & white tags
a. White tags for abnormality that can be corrected by unskilled person
b. Red tags for abnormality that can be corrected by skilled person
Keeping cleaning tools ready
fixing time for JH Activity
Cleaning all parts of the machine even opening of parts are necessary
Inspection of parts during cleaning activity
Identification and tagging of abnormality and recording
Identify difficult to access areas around the machine-In-Accessible(IA)
Identify the SOC source of contamination after cleaning
Record in the matrix red & white tags,IA,SOC

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Tools used for cleaning

Baniyan waste
To clean small burr & coolant

Nylon brush
To clean small burr & coolant

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Tools used for cleaning

Wire brush
To clean small burr & coolant

Spanners
To tighten loose bolts & nuts

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Tools used for cleaning

Showel
To clean big burr & swarf

Screw drivers
To tighten loose screws

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Tools used for cleaning

Allen Keys
To remove screws

Allen Keys
To remove hard/ solidified burr & dust

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Jishu Hozen 7 Steps

Step 1: Initial Clean up
a. Formation of JH circles
b. division of machine pars to operators
Machine no:
Circle No:
Circle Leader:
Circle Members:
1
2
3
4

Machine Parts:
1
2
3
4
5
6

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Responsibility:

Jishu Hozen 7 Steps

Step 1: Initial Clean up

Record in the matrix red & white tags,IA,SOC

Tag Matrix
Machine No:
Circle No:
Slno M/c Parts dust

Leak

Loose

Missing vibration noise

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
R

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P = Tags put

R= Tags Removed

Broken

Wornout nonStd

others

total

Jishu Hozen 7 Steps

Step 1: Initial Clean up

Record in the matrix red & white tags,IA,SOC

Source of Contaminantion
slno contaminant
1
2
3
4
5
6
7

source

Why

Why

why

Why

countermeasure

InAccessible /difficult to Clean,Lubricate,Inspect,Re-tighten - CLIR

slno Area
1
2
3
4
5
6
7

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CLIR

Why

Why

why

Why

countermeasure

Jishu Hozen 7 Steps

Step 1: Initial Clean up
Countermeasure Plan for Red/white/IA/SOC
slno

abnormality

Action Plan

Tgt Dt

Resp

1
2
3
4
5
6
7
8
Tags linked to losses
No of tags
25
20
15
10
5
0

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Failure

S etup

Yield

Defect

Motion

Jishu - Hozen
Steps for developing
2.

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Countermeasure
s for sources of
problems and
difficult places

Eliminate causes for dirt

and dust.
Improve places which are
difficult to clean,
lubricate, and retightening of bolts and
nuts.
Reduce time for clean-up
and oiling.

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Jishu Hozen 7 Steps

Step 2: Countermeasures for SOC/IA/others
a.
b.
c.
d.
e.
f.
g.

Taking actions on all abnormalities

eliminating difficult to access areas
Eliminating SOC
Machine CLEAN Without Cleaning status
Various kaizens implemented
Machine ready for tentative standard preparation
Step2 audit passed
Tags Put Vs Removed - cumulative for HSL9
No of tags
250
200
150
100
50
0
Aug-04

Sep-04

Tags put

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Oct-04

Nov-04

Dec-04

Tags removed

Jan-05

JH 2nd step
Easy to clean / Hard to access area
Before

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After

JH 2nd Step
Before

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Easy to lubricate

After

JH 2nd step
Easy to inspect and adjust
Before

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After

Jishu - Hozen
Steps for developing
3. Establishing
Tentative
Standards for
Jishu-Hozen

Make temporary
procedures or manual of
Autonomous Maintenance
for cleanup, lubrication, retightening, checkups.
(Specify the time
allocation for various
maintenance daily or
regularly held.)

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Tpm.training

Jishu Hozen 7 Steps

Step 3: Preparation of Tentative standards
a.
b.
c.
d.
e.
f.
g.
h.

Making a list of Cleaning, Lubrication,Inspection & Re-tigthening points

arriving at method and frequency of CLIR
dividing the CLIR into mahine zones
Preparation of standards chart with visual aids
Education of operators on standards
Practising the standards for minimum 1 month
Update new check points
Have step 3 audit Passes

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Jishu Hozen 7 Steps

Step 3: Preparation of Tentative standards
JH Tentative Checksheets

CLEANING

RUNNINGSTOPPED
RUNNING

60 Oper

Wk

300 Oper

Dy

60 oper

Dy

10 Oper Top up oil

Dy

10 Oper Top up oil

Dy

10 Oper

1.2 Clean burrs in bed

1.5.Clean coolant tank

INSPECTION
2.1 Hyd.oil level (should be in
green band)
2.3 Lub.oil level
Lub oil pressure(Within
green band )
2.4 Hyd.system pressure
(green band)
2.6 Abnormal noise ,heat in
hydraulic motors

Dy

Daily

2.6 Abnormal noise ,heat in

coolant motors

2.6 Abnormal noise ,heat in

lub motors

Check lub oil pressure(within

green band)

2.1 Cutting oil level (should

be in green band)

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STOPPED

Dy

1.1Clean front side of machine

Inform
supervisor
Inform
10 Oper supervisor
Inform
30 Oper supervisor

Daily

30 Oper Inform
supervisor

Daily

30 Oper Inform
supervisor

Daily

10 Oper Inform
supervisor

Daily

10 Oper Inform
supervisor

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DATE

ACTION IF
ABNORMA
L

M/C
STATUS

HOW

RESP

ACTIVITY

FREQ

SL
NO

M/C NO :
TIME
(SEC)

MONTH :

Jishu - Hozen
Steps for developing
4. Overall
Inspection

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Training in check-up skills

through checkup manuals.
Find and restore slight
defects through general
inspection.

Jishu Hozen 7 Steps

Step 4: Preparation of General Inspection
JH Step 4 Training
Topics
Sl
No.

Emp. No.

10

11

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Name

M/c No

Bolts & Nuts

Pneumatics Hydraulics Electrical

Drives

Fits/toler
ances

Safety

Process
condition

TVS-SUZUKI
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Jishu - Hozen
Steps for developing
5. Autonomous
Inspection

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Formulation and
implementation of cleanup and oiling lubricate
criteria and autonomous
inspection check sheet
which can be performed
efficiently and positively.

Jishu - Hozen
Steps for developing
6. Standardization Standardize various types of
field management items.
Establish the system to
thoroughly maintain and
control them.
Establish logistics standard
Standardization of data records
Standardization of die, tool and
jig management
Process quality assurance
standard, etc.
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Jishu - Hozen
Steps for developing
7. Autonomous
Management

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Continue to develop
corporate policy and
commitment target and
conduct Kaizen activities
regularly, and record the
data analyzed through
MTBF to improve the
equipment.

TPM Vs initiatives at Wada

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