Beruflich Dokumente
Kultur Dokumente
Autonomous Maintenance
1.
2.
3.
4.
5.
Introduction
Expected Abilities of Operators
Promote AM Step by Step
Autonomous Maintenance
Audit Criteria and the Check List of Autonomous M
aintenance
6. Three Key Points for Successful Small Group Acti
vities
7. Roles of Operators and Maintenance People
Appendix : Examples of One Point Lessons
1. Introduction
A machine breakdown does not occur suddenly. There
is a symptom of the breakdown before it takes place.
That is, it is the result of the growth of a minor defect.
PM
Including
Human
errors
PM(AM)
What do
we have
her e, a
little
f l aw?
Al l
cl eaned
and
oi l ed!
Br e a k d o wn s
Pr o d u c De f e c t s
t i vi t y
Ever yt hi ng s
i n per f ect
wor ki ng
condi t i on
t oday!
Abi l i t i es
I t must be a
l oose bol t
t hat s
causi ng t he
vi br at i on.
No, you r e
wr ong!
Ther e s a
wor n bear i ng
you shoul d
check!
The vibration
ofthe m otor
is too big !
the vibration
ofthe m otor
occurred
because of
loose nuts.
check
point
abnorm al
norm al
Don' t
Make
t he
l et
t he machi ne
di r t y.
get
as
to
St ep 2: The
oper at or
st r uct ur e
Structural diagram
knows t he f unct i on
of equi pment .
Real l y know t he
f unct i ons and st r uct ur e
of your equi pment .
and
Centering of
pooleys and
gears
Exchange of
bearings
Prevention of
oilleakage
Workplace
organization
Autonomous and
inspection
housekeeping
Step 4
General
inspection
Step 3
Tentative
standards
Step 2
p1
Fully
implemented
autonomous
management
Countermeasures
against sources
Initial cleaning
Reactive
Preventive
21
Proactive
1.
2.
Perform Initial
cleaning
Address
contamination
sources and
inaccessible places
Activities
3.
Establish leaning
and checking
standards
4.
Conduct general
equipment
inspection
Step
Activities
5. Perform general
process inspection
6. Systematize
autonomous
maintenance
7
6
Practice
full selfmanage
ment
Systematic
autonomous
maintenance
5
4
3
2
1
Perform general
process
inspection
Conduct general
equipment inspection
Production
based on the
given schedule
(focus :
production)
Recognizes signs of
abnormality; deals with
abnormalities correctly;
performs periodic overhaul
checking and parts
replacement correctly
Quality
assurance
(focus :
process)
Detects abnormalities
promptly; takes emergency
action against abnormalities
Management of
deterioration
and restoration
(focus :
machine to
process)
Understands properties of
materials being handled;
performs correct adjustment and
setting
Basic
conditions to
prevent
deterioration
(focus :
24
Operation only
Multi-operations
2 + QC + AM
3 + Improvement
4 + Engineering
25
Autonomous maintenance
When equipment does not have the basic condition to be operated and
there are many possible causes which may lead to breakdowns, a collective
approach by AM without persistently asking why, why, - - - to
identify root
causes, can work well. But when there are few breakdowns, AM can be
very costly.
26
Autonomous maintenance
When equipment does not have the basic condition to be operated and
there are many possible causes which may lead to breakdowns, a collective
approach by AM without persistently asking why, why, - - - to
identify root
causes, can work well. But when there are few breakdowns, AM can be
very costly.
thoroughness
continuity
Actual decisive factor is smooth integration with the
following two WCM fundamental activities :
The Goals of AM
* Checking ofoperating
condition
* Daily checking
* Periodicalchecking
Activities to
prevent
deterioration
* Cleaning
* Inspection
* Bolting
Activities to
restore
deterioration
Tr oubl e
Cause
1.
Lubr i cat i on
Lubr i cat i on oi l ,
gr ease
Sei ze
Lack of
l ubr i cat i on oi l ,
I mpr oper oi l
2.
Bear i ng
Bal l , Rol l er ,
Pl ai n bear i ng
Sei ze, Vi br at i on
Lack of
l ubr i cat i on oi l ,
Over l oad,
Eccent r i ci t y
3.
Body of
r ot at i on
I mpel l er , Rot or
Unbal ance
4.
Connect i on
Br eakage,
Vi br at i on
Eccent r i ci t y,
negl ect ed wear
5.
Tr ansmi ssi on
V bel t , Chai n,
Cl ut ch
Sl i di ng, Heat
6.
Seal i ng
Leakage,
Expl osi on, Fi r e
7.
Dust
pr ot ect i on
Fi l t er st r ai ner
Bl ocki ng
8.
Fl ui d cont r ol
Abnor mal
pr essur e,
Cl oggi ng,
Abnor mal quant i t y
of f l ow, Leakage
Negl ect ed f or ei gn
body
9.
Fast eni ng
Bol t , Nut ,
Vi br at i on
I nsuf f i ci ent
Ai m of AM
The Aim of AM
Self teaching in
classroom
While seeing
teaching
material (actual
article) using
texts
Discussion of results
and supplementary
lecture
Group discussion,
Instructors
supplement lecture
Group discussion
Practice
Doubt, group
discussion of
tasks, Instructors
ask questions
Show by self
what has been
learnt
Practice
Practice of normal
work method.
Instructors correct.
Discussions of results
and supplementary
lecture
Group discussion and
discussion by all
supplementary
lecture
33
Step 0
5. Preparation Activities
4. Activity Plan
3. Teams Basic Training
2. Initial Workshop, Model Areas
tep 0
1. Permanent Team
1) COST DEPLOYMENT
2)
EQUIPMENT
CLASSIFICATION
MODEL
AREA
AA CLASS EQUIPMENT
WITH MAJOR LOSSES DUE ON COST DEPLOYMENT
35
AM
* To start : Definition of machine related waste and losses and their
measurement (OEE, OPE)
* Root causes : Lack of the basic conditions
* Classification of machines
Reactive
Preventive
Proactive
AA
Some amount of
possible losses
36
800
D matrix
700
k/anno
600
500
400
300
200
100
0
208
222
203
207
205
202
204
201
223
221
UTE
D MATRIX
Breakdown analyzed by EWO format
900
800
700
AM
k/Y
600
PD
FI
PM
AM
500
400
300
200
100
0
208
222
203
207
205 202
UTE
204
201
223
221
37
Before training
Spidalieri
After training
Mengo
W CM
3
TPM
Mengo
Spidalieri
METODO AM
(7 STEP)
Team
1
Ca mbio tipo
AM TAGS
WCM
3
WCM
3
Attrezza mento
Attrezza mento
TPM
TPM
5 WHYS
METODO AM
(7 STEP)
METODO AM
(7 STEP)
Ge stione
ciclo
1
Cambio tipo
AM TAGS
Conosce nza
proce sso
OPL
Cambio tipo
Gestione
ciclo
EQU. ABC
CLASSIF.
OEE
AM TAGS
Gestione
ciclo
a ltri
TOOLS
(ka ize n, 5S , Poka Yoke, 5W 1H)
5 WHYS
5 WHYS
Conoscenza
processo
OPL
EQU. ABC
CLASSIF.
OEE
Conoscenza
processo
OPL
altri
TOOLS
(kaizen, 5S, Poka Yoke, 5W 1H)
EQU. ABC
CLASS IF.
OEE
altri
TOOLS
(kaizen, 5S, Poka Yoke , 5W1H)
La Vigna
Aprile
Attrezzamento
Attrezzame nto
TPM
METODO AM
(7 STEP)
Procedure di ripristino
La Vigna
Aprile
WCM
3
WCM
3
WCM
3
TPM
AM TAGS
Conoscenza
processo
Gestione
ciclo
WCM
3
Attrezzamento
OPL
Procedure di ripristino
METODO AM
(7 STEP)
EQU. ABC
CLASSIF.
OEE
altri
TOOLS
(kaizen, 5S, Poka Yoke, 5W1H)
5 WHYS
TPM
Conoscenza
processo
OPL
EQU. ABC
CLASSIF.
OEE
Procedure di ripristino
altri
TOOLS
(kaize n, 5S, Poka Yoke, 5W1H)
Cambio tipo
TEAM
AM TAGS
METODO AM
(7 STEP)
AM TAGS
0
5 WHYS
TPM
Cambio tipo
0
Gestione
ciclo
W CM
3
Attrez zamento
1
Cambio tipo
METODO AM
(7 STEP)
Attrezzamento
METODO AM
(7 STEP)
Procedure di ripristino
Cambio tipo
5 W HYS
0
AM TAGS
0
Gestione
ciclo
Ge stione
ciclo
5 WHYS
Conoscenz a
processo
OPL
Conoscenza
processo
OPL
EQU. ABC
CLASSIF.
altri
TOOLS
(ka ize n, 5S, Poka Yoke, 5W1H)
OEE
EQU. ABC
CLASSIF.
OEE
altri
TOOLS
(kaizen, 5S, Poka Yoke, 5W1H)
Cambio tipo
Iacobucci
WCM
3
Attrezzamento
AM TAGS
Iacobucci
WCM
3
Gestione
ciclo
TPM
Attrezzame nto
METODO AM
(7 STEP)
Procedure di ripristino
Caradonia
W CM
3
METODO AM
(7 STEP)
Procedure di ripristino
Caradonia
5 WHYS
TPM
Attrezzamento
W CM
3
METODO AM
(7 STEP)
Attrezzamento
METODO AM
(7 STEP)
2
1
Cambio tipo
AM TAGS
Cambio tipo
OPL AM TAGS
Procedure di ripristino
5 WHYS
Conoscenza
processo
Gestione
ciclo
EQU. ABC
CLASSIF.
OEE
Cambio tipo
5 W HYS
5 WHYS
Cambio tipo
5 WHYS
altri
OPL
TOOLS
(kaizen, 5S, Poka Yoke, 5W1H)
EQU. ABC
Gestione
ciclo
CLASSIF.
OPL
Conoscenza
processo
altri
TOOLS
(kaize n, 5S, Poka Yoke, 5W1H)
altri
TOOLS
(kaizen, 5S, Poka Yoke, 5W1H)
AM TAGS
EQU. ABC
CLASSIF.
OEE
Conoscenza
processo
OPL
Procedure di ripristino
AM TAGS
Gestione
ciclo
OEE
Conoscenza
processo
Gestione
ciclo
OPL
EQU. ABC
CLASSIF.
Conoscenza
processo
altri
TOOLS
(ka ize n, 5S, Poka Yoke, 5W 1H)
OEE
EQU. ABC
CLASSIF.
altri
TOOLS
(kaizen, 5S, Poka Yoke, 5W1H)
OEE
Colasanto
Caiola
Attrezzamento
TPM
METODO AM
(7 STEP)
Procedure di ripristi no
WCM
3
WCM
3
WCM
3
Attre zzamento
Colasanto
Attrezzamento
TPM
METODO AM
(7 STEP)
Procedure di ripristino
METODO AM
(7 STEP)
Procedure di ripristino
Caiola
WCM
3
Attrezzamento
AM TAGS
AM TAGS
AM TAGS
5 WHYS
Conoscenza
processo
5 WHYS
OPL
OEE
5 WHYS
Conoscenza
processo
WCM
3
Attrezzamento
METODO AM
(7 STEP)
Di Nunzio
WCM
3
Attrezz am ento
TPM
METODO AM
(7 STEP)
Procedure di ripristino
Cambio tipo
AM TAGS
Conoscenza
processo
OPL
EQU. ABC
CLASSIF.
altri
TOOLS
(kaizen, 5S, Poka Yoke, 5W1H)
AM TAGS
5 WHYS
Conoscenza
processo
OPL
EQU. ABC
CLASSIF.
altri
TOOLS
(kaizen, 5S, Poka Yoke, 5W 1H)
TOOLS
(kaizen, 5S, Poka Yoke, 5W1H)
Martino
Attrezzame nto
WCM
3
TPM
Cambio tipo
5 W HYS
Cambio tipo
AM TAGS
0
Gestione
ciclo
Ge stione
ciclo
Conosce nz a
proce sso
METODO AM
(7 STEP)
Procedure di ripristino
Gestione
ciclo
OEE
OEE
METODO AM
(7 STEP)
AM TAGS
5 WHYS
EQU. ABC
CLASSIF.
altri
Cambio tipo
0
Gestione
ciclo
OPL
Conoscenza
processo
2
Procedure di ripristino
EQU. ABC
CLASSIF.
altri
TOOLS
(kaizen, 5S, Poka Yoke, 5W1H)
OEE
W CM
3
TPM
EQU. ABC
CLASSI F.
Martino
Gestione
ciclo
OPL
Conosce nza
processo
altri
TOOLS
(kaizen, 5S, Poka Yoke, 5W1H)
Di Nunzio
5 WHYS
0
Gestione
ciclo
OPL
OEE
a ltri
TOOLS
(kaizen, 5S, Poka Yoke , 5W1H)
Cambio tipo
Gestione
ciclo
EQU. ABC
CLASSIF.
OEE
Cambio tipo
0
Gestione
ciclo
Procedure di ripristino
AM TAGS
1
1
1
Cambio tipo
Attrezzamento
METODO AM
(7 STEP)
Procedure di ripristino
5 WHYS
OPL
38
OEE
EQU. ABC
CLASSIF.
altri
TOOLS
(ka izen, 5S, Poka Yoke , 5W 1H)
Conoscenza
processo
OPL
OEE
EQU. ABC
CLASSIF.
altri
TOOLS
(kaizen, 5S, Poka Yoke, 5W1H)
St ep 1
St ep 1: Per f or m I ni t i al Cl eani ng
Cor r ect mi nor f l ows and est abl i sh basi c equi pment
condi t i ons
Activities
St ep1:
Per f orand
m i Staff
ni t i al(fostering
cl eani ng
Roles of
Managers
motivation, ability, and opportunity)
STEP 1
Practice full selfmanagement
Preliminary
activities
inspection
Step 4
Cleaning is inspection.
Why cl ean ?
Qual i t y
Def ect s
Qual
cont
mat t
mal f
Accel er at ed
Det er i or at i on
Speed Losses
( 1) Cl eani ng of t he f l oor
On t he f l oor
St ar t i ng f r om cl eani ng of t he f l oor
Mai n st eps
:
1. Fi r st , cl ean by br ooms
2. Dr aw sect i on l i nes
3. Tr y t o shut out dust
and st ai n
4. Ver y f i ne cl eani ng
1.
Fi r s t , c l ean by br ooms
2.
Dr aw s ec t i on l i nes
3.
Poi nt s I nv ol v ed:
El i mi nat i ng t he pr obl em
of cl eani ng har d- t o- r each
pl aces
Ex pec t ed Benef i t s :
har d t o cl ean
easy t o cl ean
cover
Thi s cl ear s t he
f l oor , maki ng i t
easy t o cl ean
Poi nt s I nv ol v ed:
Ex pec t ed Benef i t s :
St op t he oi l l eak
and el i mi nat e t he
oi l pan!
Us i ng an oi l pan
has kept t he
sur r oundi ng ar ea
cl ean, but t he
cause of oi l l eak
i t sel f has not been
sol ved
To do t hi s:
1.
2.
3.
4.
4.
Fi ne l evel of
cl eani ng
Tr y t o f i nd out
t he t r ue causes f or
dust or st ai n - - Col l ect def ect i ve
sampl es and check by a mi cr oscope.
Anal yze t he r out es of t he out br eak,
i nvasi on, and cont agi on of dust and
st ai n.
Thor ough cl eani ng of t he envi r onment s .
sur f ace of
upper par t
ves
ner s
* Exampl es of bl i nd poi nt s :
sheet met al
pr essi ng:
I t i s easy t o r ecogni ze t hat t he r out es
of i nf ect i on of dust comi ng i n and
causi ng t r oubl es ar e enor mous.
Moul d
A wi r e t ouches t he
f l oor or
i s pl aced on t he
f l oor
A moul d t ouches t he
gr ound
when dr i ven by t he
cr ane
Tr anspor t at
i on
A pr ot ect i on
boar d i s
pl aced di r ect l y
on t he
f l oor
Wi pe t he shoot by
a wast e
f or ei gn body l i ke
bur r )
Al i en subst ances
st i cks t o
set t i ng t ool s or
measur i ng
t ool s
Set t i ng of
t he
moul d
For ei gn body on
t he
moul d sur f ace
For ei gn body
on t he
Mat er i al
I n or der t o put a
wi r e ar ound a
moul d, a wor ker
st ands on i t wi t h
hi s shoes
Bur r by
shear i ng,
bor i ng, or
pi er ci ng
Wooden wast e comes
out
f r om br oken wooden
sur f ace pl at e
For ei gn body on
a gl ove i s
adher ed t o
For ei gn body i s
br ought
i n at t he t i me
of oi l char ge
For ei gn body on
a conveyor bel t i s
adher ed t o
For ei gn body of
a
l eat her gl ove i s
r ubbed
agai nst t he
mat er i al
mat er i al
sur f ace
Unevenness c aus ed
by al i en
s ubst anc es
Sour c e of dust
On pal l et s f r om
out si de t he
pl ant
I f I cl ean my
equi pment
t hor oughl y, I
won t over l ook
mi nor f l aws.
Poi nt of cl eani ng
( Gl asses of an oi l l evel er and
i nst r ument )
Cannot see t he
exi st ence of oi l
and t he degr ee of
cont ami nat i on
Oi l
l evel er
Cannot see
t he scal e
I nst r ume
nt s
Poi nt of cl eani ng
( Li mi t swi t ches)
Remove at t ached dust and di r t .
Poi nt of cl eani ng
( Lenses of a phot o cel l )
Cl ean wi t h a sof t cl ot h. .
Tur n
cl eani ng
i nt o
i nspect i o
n.
Equi pment
St op
accel er at ed
det er i or at i
on!
Equi pment
St op
checks
ar e a
chance
to
di scover
abnor mal
i t i es
and
det er i or
at i on!
Exampl es
1. Mi nor Fl aws
Adhes i on
2. Unf ul f i l l ed Basi c
Condi t i ons
Lubr i
Lubr i
Oi l l
Ti ght
cat i on
cant s uppl y
evel gauges
eni ng
3. I naccessi bl e Pl aces
Cl eani ng
Check i ng
Lubr i cat i ng
Ti ght eni ng
Oper at i on
Abnor mal i t y
4. Cont ami nat i on
Sour ces
Pr oduct
Raw mat er i al s
Lubr i cant s
Gases
Li qui ds
Sc r ap
Ot her
For ei gn mat t er
Shock
Moi st ur e
Gr ai n si ze
Concent r at i on
Vi scosi t y
Exampl es
Leaks, spi l l s, spur t s, scat t er , over f l ow
Leaks, spi l l s, spur t s, scat t er , over f l ow
Leaki ng, spi l l , and seepi ng l ubr i cat i ng oi l s, hydr aul i c
f l ui ds, f uel oi l , et c.
Leaki ng compr essed ai r , gases, st eam, vapor s, exhaust
f umes, et c.
Leaki ng, spi l t and spur t i ng col d wat er , hot wat er , hal f f i ni shed pr oduct s, cool i ng wat er ,
wast e wat er , et c.
Fl ashes, cut t i ngs, packagi ng mat er i al s, and nonconf or mi ng
pr oduct
Cont ami nant s br ought i n by peopl e, f or k- l i f t t r ucks, et c.
and i nf i l t r at i ng t hr ough cr acks
i n bui l di ng
I ncl usi on, i nf i l t r at i on, and ent r ai nment of r ust , chi ps,
wi r e scr aps, i nsect s, et c.
Dr oppi ng, j ol t i ng, col l i si on, vi br at i on
Too much, t oo l i t t l e, i nf i l t r at i on, def ect i ve el i mi nat i on
Abnor mal i t i es i n scr eens, cent r i f ugal separ at or s,
compr essed- ai r separ at or s, et c.
I nadequat e war mi ng, heat i ng, compoundi ng, mi xi ng,
evapor at i on, st i r r i ng, et c.
I nadequat e war mi ng, heat i ng, compoundi ng, mi xi ng,
Abnor mal i t y
6. Unnecessar y and Nonur gent i t ems
Machi ner y
Pi pi ng equi pment
Measur i ng i nst r ument s
El ect r i c al equi pment
Ji gs and t ool s
Spar e par t s
Makes hi f t r epai r s
Exampl es
Pumps, f ans, compr essor s, col umns, t anks, et c.
Pi pes, hoses, duct , val ves, damper s, et c.
Temper at ur es, pr essur e gauges, vacuum gauges, ammet er s,
et c.
Wi r i ng, pi pi ng, power l ead, swi t ches, pl ugs, et c.
Gener al t ool s, cut t i ng t ool s, j i gs, mol ds, di es,
f r ames, et c.
St andby equi pment , spar es, per manent st ocks, auxi l i ar y
mat er i al s, et c.
Tape, st r i ng, wi r e, met al pl at es, et c.
7. Unsaf e pl aces
Fl oor s
St eps
Li ght s
Rot at i ng machi ner y
Li f t i ng gear
Ot her
2.
3.
eakage on t he r od
Check items
1.
Tagging
Higher pressure.
Slow
Does not move.
6.
8.
Detagging
Check items
Tagging
Detagging
tank.
How is movement?
11.
13.
7.
9.
Take countermeasures
against dispersion of
produced chips.
15.
Good.
None
Appropriate
Make one-point
lessons.
Teachi ng
t eammat es
wi t h a
one- poi nt
l es son
I nspect i on
Why inspect ?
I nspect i on
Thr
ough cl eani ng, even a nonspeci al i st can det ect some def ect
whi ch ot her wi se may not be not i ced.
y
ilit
Fac et
N ncy
icie
f
Ef
Inspection
by cleaning
Defect
Productive
The oi l
suppl y
pi pe i s
t ouchi ng
it!
Ther e s
cut t i ng
oi l on
t he l i mi t
swi t ch
* Mai n i t ems:
St udy t he si t uat
bef or ehand.
I nspect i on by cl
Par t i ci pat i on of
t echni ci ans.
I nvest i gat i on of
def ect s.
i on
eani ng.
speci al i zed
mi nor
what
pl ant and what ki nd of t r oubl es
ar e t aki ng pl ace.
The causes of t he mai n t r priar
oubl es
investigation
ar e t o be
i nvest i gat ed.
Col l ect i t ems t hat ar e supposed
t o cause t he t r oubl es.
Tank
Pi p
e
Each oi l
s uppl y
sect i on
1. Check i f i t i s di r t y ar ound
t he end of t he oi l suppl y
pi pe or check i f t he cover i s
not br oken.
2. check t he oi l wi t hi n t he t ank
( compar ed wi t h new oi l ) .
Hydr aul i c
equi pment
Oper at i ng
oi l t ank
Oper at i ng
oi l pump
Cont r ol
pi pes
Act uat
or s
Pneumat i c
equi pment
A set of 3 ai r
suppl y
equi pment
Cont r ol
pi pes
Act uat o
rs
Ai r
escape
Mai n check
1. Check i f
f i l t er i s di
char ged
bowl i s not
di r t y.
poi nt s:
t he dr ai n wi t hi n t he ai r
sor i f t he i nsi de of t he
i on
ans
al ,
or f
Production
technicians
Facility
technicians
Other expert
technicians
* I nspect i on by cl eani ng i s t he
ent r ance t hat l eads t o t he
sol ut i on of chr oni c t r oubl es.
* However , i nspect i on by cl eani ng
does not al ways det ect al l t he
def ect s t hat cause t r oubl es.
* Ther ef or e, on t he basi s of t he
cur r ent si t uat i on of t he
f aci l i t i es, st udi ed t hr ough
i nspect i on by cl eani ng, det ai l ed
i nvest i gat i on on t he r el at i onshi p
bet ween causes and t he ef f ect f or
each t r oubl e must be car r i ed out
i n or der t o i mpr ove t he
si t uat i on.
I f you l et sl i ght l y
abnor mal condi t i ons
accumul at e, t he pr obl em
wi l l get bi gger . . .
* Mai n poi nt s
Tr oubl es on qual i t y of
t he mat er i al or t he
pr evi ous pr ocess
Ot her t r oubl es of
f aci l i t i es, moul ds, or
j i gs and t ool s
Tr oubl es by oper at i on
met hods, pr ocessi ng
condi t i ons, or handl i ng
condi t i ons
material
quality of
previous
process
moulds
Handling
conditions
Machining
conditions
Operation
jigs tools
facilities
Dampen shock
Seal out di r t
Lubr i cat e.
Ti ght en.
Finding 113
troubles
Fi
ndi
ng ai
r
l
eakage at 10
spot
s
eat
h
g
in
s
Feelhe pipe
at t
Fi
ndi
ng 91
pr
obl
em s
3.
4.
9.
Pr event i on of l ooseness
1.
2.
3.
4.
2.
3.
Looseness
Pr event i on of l ooseness
Embedded bol t
1. Bol t
l ooseness
1. Damaged gr oove
Scr ew, bol t ,
et c
2. Damaged wr ench
3. Damaged scr ew
t hr ead
4. Losseness
5. Washer , et c
2.
3.
2.
3.
4.
5.
I s i t possi bl e t o check oi l
quant i t y t hr u t he oi l l evel gauge
( posi t i on, t he degr ee of
cont ami nat i on) ?
Ar e t her e i ndi cat i on of t he upper
and l ower l i mi t s of oi l quant i t y?
Ar e t her e i ndi cat i on of t he upper
and l ower l i mi t s of pr essur e on t he
pr essur e gauge?
I sn t t her e abnor mal noi se or
over heat i ng i n pumps and mot or s?
I sn t t her e oi l l eakage?
2.
3.
4.
Defective ball
2.
Deformation
3.
Cap
Grease cup
1.
Blockage
2.
Defective cap
2.
3.
4.
V bel t s
1. No scr at ches, br eakage, oi l
cont ami nat i on or excessi ve wear ?
2. Ar e t ensi on of mul t i - bel t s
const ant ?
3. No shi ni ng at t he bot t om of t he
gr ooves of V pul l ey?
No pl ay at t he bear i ngs, or no
abnor mal noi se?
2.
3.
3.
4.
Ar en t
Pneumat i c uni t s
1.
2.
3.
4.
Ar e ai r set s of t hr ee pi eces
pr oper l y i nst al l ed so t hat t hey can
be checked easi l y?
No over heat i ng, abnor mal noi se i n
el ect r o- magnet i c val ves?
Ar e l ooseness pr event i on met hods
appl i ed t o t he scr ews of cyl i nder
r ods?
No ai r l eakage?
2.
5. Ar e l ocki ng nut s of r el i ef
val ves / speed cont r ol l er s t i ght
enough?
6. Ar e devi ces, pi pes pr oper l y
i ns t al l ed? No oi l l eakage?
7. No abnor mal noi se, over heat i ng i n
el ect r o- magnet i c v al v es?
Pi pi ng
1.
2.
3.
4.
No l ooseness i n pi pi ng and i t s
cl ampi ng?
No f r i ct i on of hoses of hi gh
pr essur e?
Ar e cyl i nder s i nst al l ed pr oper l y?
Ar en t t hey i nst al l ed l oosel y?
Ar e l ooseness pr event i on met hods
appl i ed t o t he scr ews of cyl i nder
r ods?
2.
3.
No br oken
Ar en t t her e
2.
3.
4.
5.
Wi r i ng/ cabl es
1.
2.
3.
4. 11
4. 12
4.
4.
4.
4.
4.
St ep 2
Goal s f or Cont ami nat i on Sour ces and
I naccessi bl e Pl aces
13 Pi npoi nt and El i mi nat e Sour ces of Leaks
and Spi l l s
14 Fr om Compul sor y Det er i or at i on t o
Nat ur al Det er i or at i on
15 Af t er I ni t i al Cl eani ng
16 Count er measur es agai nst t he Sour ces of
Dust and Di r t and t he Di f f i cul t Ar eas t o
Access
1) Removi ng
2) Bl ocki ng
3) Gui di ng
4) Usi ng l ocal i zed cover s
17 Sour ces of Dust and Di r t
St ep 2
Activities
Reduce housekeepi ng
el i mi nat i ng sour ces
pr event i ng scat t er ,
par t s t hat ar e har d
l ubr i cat e, t i ght en,
t i me by
of dust and di r t ,
and i mpr ovi ng
t o cl ean, check,
or mani pul at e
Maj or act i vi t y
7- 1
7- 2
7- 3
7- 4
(-Continued)
8- 1
8- 2
8- 3
8- 4
10
11
12
13
source of dust
Step 2
tep 2
I mpr ovi ng
naccessi
I mprIove
accessibibil li it tyy of
pl aces t hat ar e har d t o :
* cl ean
* check
* l ubr i cat e
* t i ght en
* oper at e
* adj us t
"Compulsory
deterioration" caused
by operator's
improper act.
Take countermeasures
at the source of
problems by
localization and
change "compulsory
deterioration" into
"natural deterioration."
Af t er I ni t i al Cl eani ng
1.
2.
I mpr ovement
Conf i r mat i on of ef f ect s
factory
Trouble due to foreign
matter, dust, dirt, etc.
The floor must be
cleaned until no dirt can
be detected on stroking
with the palm of the
hand or a white glove
watersoaked mat
wate
r
tray
sweat
from
hands, etc.
Fig.
Contamination brought in on
the work itself
Contamination created by
processing the work
Countermeasures:
1.
2.
3.
4.
5.
6.
brush
grime collector
grime collector
1.
Removi ng
Count er measur es agai nst dust by
i nt r oduci ng cl eani ng br ushes
Cl eani ng br ushes
Bel t conveyor
Pr obl em : Bel t conveyor s get di r t y.
Sol ut i on : I nst al l a bel t cl eaner t o mai nt ai n cl eanness of
t he bel t conveyor .
One poi nt l esson :
pr ot ect i on cover .
Conveyor bel t
Mat er i al : har d
sponge
r ubber
( neopr ene)
Bel t cl eaner
Sponge r ubber
Spr i ng
Sponge r ubber
hol der
1. St eel cover
acr yl i c cover
2.
Br ush t o t ake of f
dust
3. Local i zed r emovabl e
cover t o col l ect dust
Br ush
Br us
h
2)
Bl ocki ng
Rubber s heet
Tappi ng machi ne
Pr obl em :
Powder dr ops ont o t he pi t at t he t i me of
f eedi ng powder i nt o a moul d. Sol ut i on :
Pr event powder
f r om f al l i ng t o t he pi t by pr ovi di ng t he moul d wi t h
bel l ows.
Moul d
Bel l ows
Tappi ng mac hi ne
3) Gui di ng
Bel t conveyor
Pr obl em : Ther e i s powder l eakage and dust gener at i on
at t he di schar gi ng
sect i on of a bel t conveyor .
Sol ut i on :
cover
Scat t er i ng
pr ot ect i on cover
Chi p t r ay
Rubbi sh dr awer
Bel t conveyor
Pr obl em :
Ther e i s over f l ow of r aw mat er i al and powder
l eakage t akes pl ace.
Sol ut i on :
Di schar ge
chut e
It is
im possible to
clean,lubricate
and inspect.
Poi nt s
I nvi ng
ol scat
v ed:t er i ng
Pr event
of
dust , et c. , at t he s our ce
of t he pr obl em
du
Ex pec t ed
Benef
i t sr:onment
I mpr
oves envi
I mpr oves qual i t y
I ncr eases pr oduct i vi t y
st
I s t he cover f unct i oni ng as a dust r emover ? Reconst r uct ed so t hat dust i s sucked i n
Let's start by
m aking a localcover
"by hand."
"Box type"
not m uch cost,
big effects.
Pr esent
Condi t i on
heat f l ap
door
di f f usi on
Af t er
I mpr ovement
Af t er I mpr ovement s:
Di f f usi on out si de t he f ur nace was
r educed by i nst al l i ng a ser i es of
3 f l aps wi t h di f f er ent l engt hs.
es
tiv
fec
De
Localization
g
pin
op
St
ow ns
d
k
a
e
r
b
ber of
m
u
n
e
h
T
Di sper si o
n of
cut t i ng
chi ps
Dust col l ect i ng
box
Ther e i s a bi g
space bet ween
t he cut t i ng
bl ade and t he
cover
Dust
col l ect i n
g i nl et
Bobbi n
chuck
Pr obl ems
Power of
absor pt i on i s
di sper sed
Chi ps ar e
scat t er ed
area B
area A
area A
I t t ak es 20 mi n/ day t o c l ean
t he s c at t er ed c hi ps j us t ar ound
t he c ut t i ng s ec t i on, and 86
mi n/ day t o c l ean t he t ot al
ar ea.
Thi s c l eani ng t i me i s t he
bi gges t l os s i t em, and 54. 8% of
al l non- v al ue added l os s t i me.
The t ot al l os t t i me due t o
c l eani ng i s 1720 mi n/ mont h.
Cut t i ng
chi ps
Bobbi n
Bobbi n
chuck
Scat t er i ng
ci r cl e gr aph
ar ea B
Wi t hi n
t he
dust
col l ec
t i ng
i nl et
ar ea A
Wi t hi n
t he
dust
col l ec
t i ng
i nl et
ar ea A
(4) 1st improvement (improvement of the bobbin chuck and the change
of the shape of the cover)
New
col l ect i ng
cover
Shape of t he
col l ect i ng i nl et
1.
2.
I mpr ovement
poi nt
Space bet ween t he cut t i ng bl ade and t he cover
minimum
Space at t he bobbi n cut t i ng sect i on minimum
(improvement of the chuck)
Suct i on l oss
1.
2.
Lef t over
pr obl ems
Chi ps st i l l come out of t he space bet ween t he cut t i ng
bl ade and t he cover .
Chi ps whi ch st i ck t o t he bl ade wi l l scat t er by t he
cent r i f ugal f or ce.
( 5) Conf i r mat i on of t he ef f ec t by t he 1s t
i mpr ov ement
Scat t er i ng
ci r cl e gr aph
Cut t i ng
chi ps
ar ea B
ar ea B
Cut t i ng
bl ade
I nsi de
t he
col l ect i n
g chi ps
i nl et
I nsi de
t he
col l ect i n
g chi ps
i nl et
Ti me r equi r ed f or
cl eani ng ar ound t he
cut t i ng sect i on
3 mi n/ day
New chi ps
col l ect i ng
cover
Saucer
Cut t i ng
chi ps
I mpr ovement
poi nt
1.
2.
Shape of t he i nl et
Chi ps
col l ect i ng
i nl et
Concent r at i on of
sucki ng f or ce
Pr event i on of chi ps
scat t er i ng
Saucer
Scat t er i ng
ci r cl e gr aph
Cut t i ng
chi ps
Chi ps
col l ect i ng
cover
The chips which have not been collected are gathered in a saucer.
1st
i mpr ovement
20. 9 cm
2
20 6
20
mi n. / day
2
2. 0 cm
5. 8
3
mi n. / day
2nd
i mpr ovement
2
0. 8 cm
0
mi n. / day
mechani s
m
heat
ant i expl osi o
n
Funct i on
Not e
Equi pment
per s on
Heat per s on
Expl osi on
per s on
Soundpr oof i ng
Noi se
per s on
I t shut s of f t he noi se of t he
equi pment .
Exhaust
Equi pment
envi r onment
Pr event i on of
spl ash
Dust
equi pment
Di r t , dust , and so on ar e
conf i ned. ( a l ocal cover )
Pr event i on of
dr op
Equi pment
f or ei gn
subst ance
(cont i nued)
Name
Funct i on
Not e
Pr ot ect i on of
equi pment
Envi r onment
equi pment
Pr event i on of
i mpr oper
oper at i on
Per son
equi pment
The oper at i on
gui dance
Oper at i on
i mpr ovement
1
0
Mai nt ai nabi
lity
i mpr ovement
A s t andar d f or i ns pec t i on
and so on i s i ndi c at ed t o
t he t r ans par enc y c over
cl ear l y. ( bel t l oos eness
l i mi t )
1
1
Appear ance
Appear ance
Desi gn
Appear ance
dirt
Ican
clear in a
short
tim e.
Localization
It is easy to
lubricate and
to inspect.
It is easy
to do
setup.
Prevention of
scattering is
im portant!
Further
challenge !
Breakdowns
and defectives have
been
reduced !!
I nspect i on t i me r educt i on
Wi ndows t o f aci l i t at e
i nspect i on
25
STEP 2
7,53
20
5,07 5,2
5,07
15
4,99
3,58
10
2,3
2,78
WEEK 18
0
WEEK 17
0
WEEK 16
0
WEEK 15
0
WEEK 14
0
WEEK 13
WEEK 12
WEEK 11
0
WEEK 10
FEBRUARY
JANUARY
DECEMBER
NOVEMBER
OCTOBER
JULY
SEPTEMBER
1,12
8
7
6
5
4
3
2
1
0 0
B/ C Anal ysi s
25
4
3,5
10
2,3
W 11
W 12
W 13
W 14
W 15
W 16
W17
W18
B/C = 2,82
B/C = 33,67
WEEK 18
WEEK 17
FEBRUARY
W 10
JANUARY
DECEMBER
0,5
NOVEMBER
OCTOBER
1,12
SEPTEMBER
1,5
2,78
WEEK 16
WEEK 15
2,1
4,99
3,58
WEEK 14
2,15
5,07 5,2
WEEK 13
2,25
WEEK 12
2,35
2,5
5,07
15
2,6
WEEK 11
2,8
JULY
Average time
20
WEEK 10
3
3
7,53
8
7
6
5
4
3
2
1
0 0
AM standard
Responsible
yes
Training to AM operators
Maintenance operator, AM
operators
no
Autonomous maintenance
standard creation
AM Standard Scheduling
AM Standard check
AM Standard Samples
4.18 Step 3
4.19 Establish Cleaning, Lubricating and Inspection Standard
s
4.20 How to Reduce Time Required for Cleaning
4.21 How to Reduce Time Required for Inspection
4.22 How to Reduce Time Required for Lubricating
4.23 AM Calendar
4.24 How to Make Check Lists
4.25 Introduce Extensive Visual Controls
4.26 Step 4
4.27 Step 5
4.28 Step 6
4,29 Step 7
Step 3
Activities
Ensur e t hat
and l ear n t
under st and
i s) by havi
oper at or s
hei r i mpor t
what wor kpl
ng t hem set
obey st andar ds
ance ( i . e. ,
ace management
t hei r own
Gi ve hi nt s on wr i t i ng and pr esent i ng
cl eani ng and i nspect i on st andar ds
Gi ve t echni cal assi st ance i n
pr epar i ng l ubr i cat i ng st andar ds
Descr i be how vi sual cont r ol s can
si mpl i f y checki ng, and gi ve pr act i cal
advi ce
1.
2.
3.
4.
5.
Subst ep
Maj or
act i vi t y
Conduct educat i on f or
l ubr i cat i on.
I dent i f y l ubr i cat i on poi nt s
and sur f aces.
Al l ocat e r out i ne l ubr i cat i ng
t asks.
Set t ent at i ve l ubr i cat i ng
t asks.
Est i mat e l ubr i cat i ng
i nt er val s.
6.
Subst ep
Maj or
act i vi t y
Set l ubr i cat i ng t i me t ar get s.
7.
8.
2.
3.
4.
I dent i f y l ubr i
s our c es .
Pl an r emedi al
Tak e r emedi al
Ev al uat e r es ul
c at i on r el at ed
ac t i ons .
ac t i ons .
t s of ac t i ons .
9.
Subst ep
act i vi t y
Equi pment def ect s:
1.
2.
Maj or
12.
13.
14.
15.
Subst ep
Maj or
act i vi t y
Compar e wi t h l ubr i cat i ng
st andar ds set by f ul l - t i me
mai nt enance.
Set cl eani ng and l ubr i cat i ng
st andar ds.
Devel op a shor t r emedi al pr ogr am.
Conduct an aut onomous mai nt enance
audi t .
Step 3
5. Perform accurate checking by means
of visual controls
4. Sustain the three basic conditions for
maintaining equipment and preventing
deterioration (cleaning, lubricating, and
inspection).
3. Give technical assistance in preparing lubricating
standards
p3
Topsds
t andar
efnev
olo lmowed
The down
standar
m adeds
by ar
staf
are er
hardf t
aintain.
It takes so
long to clean !
Transparent
acrylic board
* Num ber of
belts
* W ear,dust
and dirt
* Tension
2. Pl ace t he
i nspect i on
spot at t he
hei ght of
oper at or ' s
3. Meyes.
ake t he
hi dden par t s
vi si bl e.
*Vibration
*tem perature
Easy to
inspect
strainer
strainer
Lubricate
* with clean oilin right quantity
* at the right charging spot
* at scheduled tim e.
Oilis
running
short !
Breakdown
Im proper oilcharge
O il
leakage Bad
lubrication
Seizing
( 1)
( 2)
( 3)
( 4)
( of
sui t abl e
oi l )
( at r i ght
t i me)
( by pr oper
met hod)
( wi t h r i ght
quant i t y)
There are
too m any
lubrication
spots.
Autom atic
lubricating system
To each
lubrication spot
Cent r al i z ed oi l
char gi ng
Carrier guide
Distribution pipe
Main pipe
Greasing pump
Distribution valve
Paper
Gear
Timing belt
Aut omat i on f or oi l
char gi ng
Oil charge
by hand
Automatic
lubrication
frame
Operation side
Machine
* Bearing
AM Cal endar
I mpl ement per i odi c aut onomous mai nt enanc e, moni t or
r es ul t s and r ev i ew i nt r oduc e aut onomous mai nt enanc e
c al endar .
I nspect i on i t ems.
Key poi nt s.
Met hod.
Tool s.
Ti mes.
I nt er val s.
Responsi bi l i t y.
3. 3
Fi gur e :
Cl eani ng and Lubr i cat i on St
andar ds
( Tokai Rubber I ndust r i es)
No.24
Expiration date:12/81
Friction gear
O illevel
Cleaning areas
Category
Around m ain fram e
Oilwindow
Category
Lubricator
Friction gears
Large gearwheel
Lubrication checkpoints
Plant m anager:
Section chief:
PM engineer:
Forem an:
Cleaning
m ethods
Cleaning
equipm ent
Raw m aterials
plant
Cleaning
tim e
No scattering of
rubber scrap
Sweep away
with broom
5 m in.
O illeveleasy to check
3 m in.
No oiland dirt
10 m in.
Day W k. M o.
No rubber scrap
adhering to fram e
Cleaning cycle
15 m in.
30 m in.
Lubrication standards
Lubrication
m ethods
Pour by hand
O illevelhalf-way up
gear teeth (#32)
O ilcan
5 m in.
Gearwheelwell-lubricated
(open gearwheel)
Drip in through
oilsupply port
with spatula
5 m in.
Use oil
applicator
3 m in.
10 m in.
Oi l Pr essur e Pump
Check I t ems
Check I t ems
3. No pl ay i n pi n
7. Lever mot i on wi t hi n l i mi t
val ues
-
Check
I t ems
I nspect i on
Resul t s
Check
I t ems
I nspect i on
Resul t s
1. Cor r ect
Posi t i on
st op
nor mal
posi t i on
OK
5. No
debr i s
on
movi ng
par t s
None
2.
Posi t i on
nor mal
OK
6. Vol t age
and
cur r ent
wi t hi n
r at ed
val ues
Rat ed:
OK
AC 200 V
2A
Act ual :
198 V 1. 2A
3. No
pl ay i n
pi n
No pl ay
OK
7. Lever
mot i on
wi t hi n
l i mi t
val ues
St andar d:
wi t hi n 90
Act ual :
wi t hi n 60
OK
4. Rol l er
on
t r ack,
no
On t r ack
OK
8. No
l i qui d
or vapor
on
Some
cool ant on
swi t ch,
but i t s
Cor r ect
l i mi t
swi t ch
posi t i on
OK
Inspection Results
Check Items
Inspection Results
1. Discharge
pressure
set
correctly?
standard:
202 kg/cm2
actual:
20.5 kg/cm2
OK
5. Coupling
normal?
Yes
OK
2. Normal
Within level
amount of range
oil in tank?
OK
6. Pump and
motor
axes
cantered?
standard
1mm
off center
actual: .08mm
off center
OK
3. Strainer
free of
debris?
very clogged
7. Noise,
a lot of noise,
overheatin overheating,
g, or
and vibration
vibration in
pump?
4. Hydraulic
oil clean,
no air
bubbles?
8. Noise,
No
overheatin
g, or
vibration in
motor?
OK
M ainly lubrication
inspection
During operation
Inspection by
hum an sense
At the end of
work
M ainly cleaning
inspection
Wi r e mesh
Fi gur e.
Exam
Lubr i cat
i o pl
n i nl et
di spl ay
col or coded by
t ype of
l ubr i cant
e of bear i ng l ubr
i cat keep
i on
Al ways
I ndi cat es
number of
l ubr i cat i on
poi nt s
bear i ng
gr een
or ange
Col or s
may be
used f or
oi l
l evel
cont r ol
r ed
gr ease
ni ppl es
cl ean and
f i t caps
Nowher
bl ock
e ed
pi pes
possi
bl e
Us e
t r anspar ent
pi pi ng or
cl ean
Ver i f y
shaf t
annual
l ubrl i ycant
suppl y by
checki ng f or
l eaks ar ound
l ubr i cat ed
par t s
r ed
gr een
Fl oat :
l i qui d
l evel made
vi si bl e
f r om
out si de
Cl ean spool s
Cl ean gui de r ol l er s
Cl ean
di es and
ni ppl es
Cl ean
i nt er i or
of wat er
bat hs
Fi gur e.
Pi pi ng
check
st r ai
ner
I ndi cat e
per son
r esponsi bl e
on mai n
val ves t o be
cl osed on
shut down days
Use
r ever si bl e
t her mosensi
t i ve l abel
t o i ndi cat e
t emper at ur e
gauge mar k
( gr een)
Per son
Keep
f l ow di r ect i on
r espons
I dent i f y
open
i bl e
f l ui d usi ng
dur i ng
f or
JI S col or oper at
mai n
code
i on
val ve
I ndi cat e
whet her val ve
i s t o be kept
open or cl osed
Di spl ay of
r epl acement dat e on
el ect r i cal par t s
( l i mi t swi t ches,
r el ays, et c. )
Col or - codi ng of
r ecept acl es f or
t r ash, r ecycl abl e
wast e, fetl am
c.mabl e
nonf l ammabl e
Exampl e:
bel showi ng r epl acement dat e
Combust i bl e mat er i al - whi t e
l et t er s on
gr een
backgr ound
e. Exampl e of Vi sual Cont r olI ncom
s bust i bl e mat er i al -
Di spl ay of easi l y
mi st aken pr essi ng
sequence f or
but t ons
or
in
to
of f
e
ed
e and
t o be
Gauge mar k s
Sl ackness l i mi t
Di spl ay bel t si ze
er t i on of
B- 803
I nst al l i n
pumps , v al v es,
bear i ngs ,
mot or s, eset cI. ns pec t i on dat es
t her mocoupl
sl ackne
ss
l i mi t
Check f or
sl i ppage usi ng
t her mosensi t i ve
l abel
Li ght i ng mapMai
gr een
r ed
I nt er i or
Fi gur e
Make i t easy
t o t el l
whet her t he
t her mocoupl e
i s f ul l y
i nser t ed
10/ 87
12/ 87
n
swi
t ch
Dat e f or cl eani ng
and i nspect i ng
el ement . Ar e
mi cr on- si zed
f or ei gn par t i cl es
bei ng t r apped? Ar e
you not onl y
Ni ght - onl y l i ght i ng: gr een
cl eani ng, but al so Ni ght + cl oud: yel l ow
checki ng how much Ni ght + r ai n: r ed
and what ki nd of
Per son
in
geo
Maichar
n Pr
- t enanc
e
duc
tio
n
Vol t age
Dest i nat
i on
st i cker
Check f or
damage and
di r t on
pi st on
hy dr aul i c c yl i nder
2.
3.
i ndi cat i on
of use
sol enoi d val ve
oi l - l evel
gauge
wi r i ng.
Check f or
scr at ches,
cr acks,
di r t , et c.
capst an
r eal i gnment r ol l er
gui de r ol l er
gui de r ol l er
pi pe
pr essur e r ol l er
count er
gui d
e
r ol l
er
gui de r ol l er
c ont r o capst an
l
c aps tpanel
an
pr essur e r ol l er
Bobbi n wi nder
t ur nt abl e
gui de
f el t pad
Suppl y
br ak e
c- spool
Make a habi t of
doi ng t he best
dr awi ng
pos si bl e
No.
Item
Phenomenon Method
C-spools
Dirt and
surface
damage
Felt pads
Copper or iron
powder
Guide
and
realignment
rollers
Faulty rotation
Touch
Check
for
anything Scratchthat
es
feels
unusual
Look
Limit
sample
Look
Check
Scratchthat
es, faulty 14 5
mark is
winding
rotating
Quantify so far as
possible. If not
possible, check parts
using limit samples.
Figure
Standar Effect on
Type of
Department Recurrence
Number
Interval
d
quality
control
responsible prevention
Clarify relation
between defect
and
equipment.
All
When
return- Production
ing
Once a
day
Once a
day
Need for
accuracy trend
control, etc.
It is important to
indicate the
number to be
checked.
I nt er val
Dai l y
Mont h 1
Mont h 2
Mont h 3
Ti me
r equi r ed
Appr ox.
10 mi n.
Ever y
10 days
15- 20 mi n.
Mont hl y
15- 20 mi n.
Ever y
3 mont hs
15- 20 mi n.
Equipment name
No.
Maintenance item
1 FRLs
Lubrication of
2 grease
nipples
3 Rust
No.
of
sites
Day
1
30
31
Person
responsible
Robinson
25
12
Leakage
(draw maps)
Scatter (draw
Chips, dust, fumes
maps)
TYPE OF ACTIVITY
ACCORDING TO
SUPPLIERS
PROCEDURE
COMPONENT
STANDARD CODE
STABILIMENTO: VALLADOLID
U.O. CARROCERAS
U.O. CARROCERAS
CDIGO CICLO:
CDIGO CICLO:
T. CICLO: OP20A_1_2
INSPECCIN
LIMPIEZA
LUBR
T. CICLO: OP20A_1_4
INSPECCIN
LIMPIEZA
LUBR
GREEN
BLUE
YELLOW
ORANGE
COLOR
KLUBERSYNTH GH6-220
LOCTITE 8101
DESCRIPTION
CC 320
CC 460
-------
220
-------
ISO
75319506
75319506
75261824
-------
75258328
SAP
SQ22RB
SQ21RB
SQ24RB
SQ23RB
0 SQ37RB
0 SQ38RB
SQ26RB
0 0 SQ25RB
MOT VAR DX
O.S. DX
SQ28RB
0 0 SQ27RB
SQ30RB
0
WEEKLY
MONTHLY
BIMONTHLY
QUARTERLY
SIX-MONTHLY
0 0 SQ29RB
C4
ANNUAL
C3
SQ32RB
0 0 SQ31RB
M.ELEV.
RETROCESO
POS
0 O.SEG2
RETR.
0 O.SEG3
AV.
RAL STOP
0 0
CENTR.
STOP RAL
M.R.
POS
0S
0 E. ALTO
0 E. INTERM.
0B
E. BAJO
0
O.SEG1
AVANCE
0 0 SQ11RB
C2
C1
0
SQ12RB
0 0 SQ9RB
OP20A EN REPOSO
SQ10RB
0 0 SQ7RB
O.S. SX
0 SQ18RB
0 SQ17RB
LABOR ULTIMADA
SQ8RB
MOT VAR SX
0 0 SQ5RB
ANOMALIA OP20A
SQ6RB
SQ3RB
WIP OP20A
SQ4RB
SQ1RB
SQ2RB
FRECUENCIA
FRECUENCIA
1 veces cada 2 meses
AFTER
Become a human
sensor
Expand
responsibilities
Management by
objectives
Machine
4
P
Machine
1
Machine
3
Machine
2
People Development
TODAY
2752
2279
2221
2000,0
1686
1684
Costi
1500,0
Benefici
1000,0
583
500,0
0,0
Step 1
Step 2
Step 3
20
Minuti/settimana
600
10
Step 2
600
00
Attivit a macchina
ferma
Totale attivit
500
400
419
300
280
200
117,88
100
Step 1
740
Obj=125 min/sett
36
Step 3
Scraps / Step
AM Ta gs
400
350
286
300
238
250
200
150
100
143
Step 1
Step 2
Step 3
2,00
1,80
1,60
1,40
1,20
1,00
0,80
0,60
0,40
0,20
0,00
0,40
Step 1
0,42
Step 2
0,38
Step 3
Step 3
Step 4
1 INPUT:
Residual losses
Total machine losses: Rettifica De Clichy (TG745389)
2 INPUT:
People motivation
22%
losse
lo
s
OEE
Perdite totali
78%
15%
LOSSES TO ATTACK
WITH AM PILLAR
Scraps and reworks
Maintenance activities
Introduction of
new inspections
Step 4
Activities
St
ep 4: Conduct
pment i nspect
Hardware
Goals gener
(Keysalforequi
workplace
audits)i on
l i t y by
i on and
or each
and bol t
per f or mi ng
r ever si ng
equi pment
s, dr i ve
St ep of
4:Managers
Conduct gener
al equi
pment i motivation,
nspect i on
Roles
and Staff
(fostering
ability, and opportunity)
Dr aw up i nspect i on schedul es
2.
Maj or
I nspect i ve i t ems:
3. I nspect i ve:
Conduc t an ov er al l
i ns pec t i on.
Remedy def ec t i v e ar eas
di s c ov er ed.
6.
7.
8.
I dent i f y di f f i c ul t i ns pec t i ng
ar eas .
Remedy di f f i c ul t i ns pec t i ng
ar eas .
9.
Subst ep
Maj or
act i vi t y
Revi ew i nspect i ng t asks.
10.
11.
12.
13.
1.Basic knowledge of
equipm ent
* How far knowledge is
necessary?
(Clarification ofthe
range ofknowledge)
2.Training / Education
* How m uch have the
operators understood?
(Confirm ation test)
1.
2.
3.
4.
Checks heet s
Manual s
( Cut away model s,
wal l char t s,
s l i des, et c. )
Tr ai n gr oup l eader s
Mai nt enance
st af f
Tr aiPr
n epar e f or r el ay t eachi ng of
gr oup member s
Gr oup l eader s;
wor kpl ace
super vi sor s
Tr ai n gr oup member s
Gr oup l eader s
( Gener al i ns pec t i on of al l
equi pment )
Gr oup member s
Gener al Hol d gr oup meet i ngs, l i s t
I nspect abnor mal i t i es, pl an act i ons
i on
Gr oup l eader s
Cor r ect abnor mal i t i es
Gr oup member s;
mai nt enance
per sonnel
Est abl i sh pr ovi s i onal dai l y
i ns pec t i on s t andar ds
Gr oup member s
Assess i nspect i on ski l l s
Gener al
I nspect i on
Gr oup member s
Rei nf or cem
e f or m s el f - audi t and appl y
Per
nt
f or of f i ci al audi t
Abnor mal i t i es l i st s
( Det er i or at ed
par t s;
i naccessi bl e
ar eas)
Gr oup l eader s
Per f or m audi t
Wor k pl ace
Move t o nest i nspect i on
super vi sor s;
cat egor y ( appr oxi mat el y one
mai nt enance st af f
cat egor y per mont h)
Tr eat pr obl em ar eas i ndi cat ed
Gr oup member s;
mai nt enance per sonnel
Lubrication
Transmission
s
Pneumatics
Mont h 1
Mont h 2
Mont h 3
Mont h 4
TPM Pr epar at i on
Teach
Teach
Pi l ot Team
Manager s
Model Teams
e. The depl oyment of TPM act i on t eams
Equi pment
Act i on Teams
Gener al
i nspect i on of
bol t s and nut s
Ov er l ook t he
l oos ened nut .
The l ac k of t he
nut c annot be
f ound.
Bol t
Body
Thi s i s not t o
move t he upper
nut .
Gener al
i nspect i on of
l ubr i cat i on
Fr ont gl ass
Gener al
i nspect i on of
hydr aul i c/ pneumat
i c devi ces
Chec k wi t h ey es
Ar e hy dr aul i c uni t s not c ont ami nat ed by c hi ps
and c ut t i ng oi l ?
I s n t t her e any oi l l eak age f r om pumps ,
el ec t r omagnet i c v al ues or j oi nt s ?
Ar e pr es s ur e gauges pr oper ones ?
Does i t k eep a r i ght v al ue?
Ar e t he t y pes and c apac i t i es of t he pump and
t he mot or appr opr i at e?
I s t he oi l l ev el gauge c l ear ?
Ar e t he quant i t y and t he c ol or of oi l pr oper ?
I s t he c ap of t he oi l s uppl y out l et c l os ed
pr oper l y ?
Ar e t her e any s pac es or hol es i n t he mai n body
of t he t ank , f r om whi c h
dus t may c ome i n?
I s n t t he l eak ed oi l r et ur ned t o t he t ank ?
( 2)
( 4)
( 6)
Chec k wi t h ear s
Ar e t her e any r oar i ng s ounds pr oduc ed f r om pumps ,
mot or s ,
t he el ec t r o- magnet i c v al ues or pi pes ?
Chec k wi t h hand by t ouc hi ng s ur f ac es
I s t her e any v i br at i on or gener at ed heat f r om pumps ,
mot or s
or el ec t r o- magnet i c v al v es ?
Ar e t he l oc k i ng nut s of pumps , mot or s or el ec t r omagnet i c
v al v es not l oos ened?
Chec k oi l l eak age by wi pi ng t he ar ea.
Ar e t he pi pes i nt er s ec t ed or c ont ac t ed wi t h eac h
ot her ?
Chec k by r emov i ng
How i s t he wear of c upl i ngs of mot or s and pumps ?
Ar e t he ai r br eat her s of oi l s uppl y out l et c aps
appr opr i at e?
Ar e t he oi l s t r ai ner s of oi l s uppl y out l et s not t or n
Do not t wi st hoses !
When t her e i s t wi st , a punct ur e t akes pl ace.
No t wi st
Fl exi bl e
Need a cool er
Ri ght
zone
Need at t ent i on at
t he t i me of st ar t
up
Gener al
i nspect i on of
power
t r ansmi ssi on
The di st ance
Dr i vi ng
si de
Chec k by r emov i ng
I s bel t t ens i on pr oper ?
Ar e t he t y pes and t he number of bel t s and pul l ey s pr oper ?
Ar e bel t s and pul l ey s not wor n?
Ar e bol t s and k ey s of pul l ey s not l oos ened?
Ar e bel t s bet ween pul l ey s s t abl e?
Ar e mot or s and r educ t i on gear s c onnec t ed pr oper l y ?
Ar e t he c upl i ngs bet ween a mot or and a r educ t i on gear not wo
Ar en t mot or s and ai r c ool i ng f ans c l ogged wi t h dus t ?
I s t her e dus t i n t he l ubr i c at i on oi l of r educ t i on gear s ?
Movi ng di r ect i on
New
Wor n
Rol l er
Pi n
Bush
Oi l
Dr i vi ng
si de
For ei gn Wor n
body
pul l ey
Wor n
bel t
Do not al l ow V bel t s t o vi br at e l at er al l y !
When bear i ngs ar e hot , bel t t ensi on i s t oo hi gh.
t he pul l eys ar e hot , bel t
t ensi on i s t oo l ow.
Sl i ps t ake pl ace.
The causes of l at er al vi br at i on :
Eccent r i ci t y
Wear
Looseness
When
Gener al
i nspect i on
of el ect r i ci t y
Mi st
In
Ai r
pr essur e
Suct i on
pi pe
2.
3.
Gasket of t he case
4.
Damaged case
5.
6.
Oi l char ge pl ug of t heGaske
oi l er
Sc r ew
Si ght
gl ass
Oi l pl ug
Out
Gaske
tCase
Cas
e
Dr ai
n
l ock
Rel i ef
hol e
Gauge
gl ass
Bol t Lengt hs
Washer s
At t achment of
Nut s and Bol t s
Oi l - l evel Gauges
Aut omat i c
Lubr i cat i ng
Devi ces
Lubr i cat i on
Condi t i on
V- bel t s and
Pul l eys
Rol l er Chai ns
Shaf t s Bear i n
gs and
Coupl i ngs
Gear s
Hydr aul i c
Uni t s
Heat
Exchanger s
Hydr aul i c
Equi pment
Pi pi ng and
Wi r i ng
( 5) . Pneumat i c checkpoi nt s
FRLs
( 5) . Pneumat i c checkpoi nt s
Pneumat i c
Equi pment
Pi pi ng and
Wi r i ng
or
nt o
any
t
El ect r i cal
Equi pment
Ar e al l mot
vi br at i on,
Ar e al l mot
Ar e any at t
pedest al s f
Sensor s
Swi t ches
Pi pi ng and
Wi r i ng
Pump
s
Fans
2400
2426,69
2500
2000
1500
1561,38
Costi
1500
Benefici
1000
500
0
1
Costs
Inspection and cleaning
activities
Training
- Losses in productivity
Benefits
Further reduction of losses (scraps)
and consequent increase of OEE
Reduction of inspection activities made
by professional maintenance team
317
OPL
Training room
Practical Training
9 trained people
27 total training hours
318
TRAINING
INITIAL STATE
.1
.2
.3
.4
.5
.6
.7
M a n t e nim ie n t o M e c n ico
M a n t e nim ie n t o El ct r ico
M a n t e nim ie n t o N e u m t ico
Act ividades a ut on om a s
W CM
H e r r a m ie nt a s de Ca lida d
Logist ica
a ct ua l
PI LARES
re que rido
CURRENT STATE
2
2
2
3
3
3
2
2
2
2
3
3
3
2
requerido
actual
319
IVECO PRODUCTION SYSTEM
AUTONOMOUS MAINTENANCE
AFTER
Monthly substitution of
the component following
to collisions for wrong
assembly
COMPONENT COST: 37
450
Correct assembly
Component
substitution at the
end of its life-cycle
400
350
300
250
200
150
100
37
50
-
Step 1-3
Step 4
320
Component Inspections
Quality Inspections
From product control to
process control
Safety Inspections
Heinrich Pyramid
New unsafe act and
conditions identified
2006
2007
FATALITY
Fatality
LWDC 3 DAYS
FAI
NEAR MISSES
321
Usura punta da
contatto per mancata
lubrificazione
Controllo bloccaggio
della contropunta
mediante manometro
322
Step 4: results
Cleaning and Inspection Time
800
2279
2221
2000
1684
Costi
Benefici
1419
583
1000
1686
Step 1
Step 2
Step 3
700
2022
Step 4
Minuti/settimana
3000
740
600
600
500
419
400
Attivit a macchina
ferma
Totale attivit
280
300
192,81
200
117,88
100
36
Obj=210 min/sett
59,19
0
1 STEP 2 STEP 3 STEP 4 STEP 5 STEP
STEP
Scraps / steps
2,00
1,80
1,60
1,40
1,20
1,00
0,80
0,60
0,40
0,20
0,00
AM Tags
400
350
286
300
238
250
0,40
0,42
0,38
0,26
200
150
Step 1
Step 2
Step 3
Step 4
302
143
100
Step 1
Step 2
Step 3
Step 4
Step 4: results
Step 4
Step 5
Total machine losses: Rettifica De Clichy (TG745389)
15,5%
OEE
Perdite totali
84,5%
5%
Maintenance activities
Reduction of cleaning
and inspection times
324
Sep 5
Activities
2.
3.
4.
5.
Maj or
Maj or
Lubrication system
This is the
m ost im portant check
point !
Breakdowns
can be avoided
ifyou check
this point.
Equipm ent
can be
restored by
the periodic
repair !
Pr epar e
per f or mance
and f unct i on
l essons
Rel ay
Rel ay OJT
t eachi ng
St af f St af f gr oup l eader sgr oup l eader sgr oup member s
gr oup member s
Rei nf or ce
( pr act i cal
t est s)
Rei nf or ce
( i ndi vi dual
t est s)
I dent i f y
adj ust ment
and set t i ng
keys
Pr epar e
adj ust ment /
set t i ng manual s
Rel ay OJT
St af f gr oup l eader sgr oup member s
Rei nf or ce
( pr act i cal
t est s)
Est abl i sh
Cl ar i f y
cur r i cul um uni t s I dent i f y l i kel y r esponsi bi l i t y f or
f or chemi cal
sour ce of
per i odi c checks
engi neer i ng
ser i ous acci dent s
and par t s
basi cs
r epl acement
Pr epar e
l esson sheet s
Rel ay
St
gr oup
gr oup
t eachi ng
af f l eader smember s
Rei nf or ce
( i ndi vi dual
t est s)
Rel ay
St
gr oup
gr oup
t eachi ng
af f l eader smember s
Pr ompt
det ect i on
Emer gency
measur es
Rel ay OJT
St af f gr oup l eader sgr oup member s
Pr ocess
composi t i on
( equi pment )
Per f or mance
Funct i on
Rol e
Specs.
Rel at i on
to
qual i t y
Why
necessar y?
Any l osses?
I mpr ovement
pr oposal s
( si mpl i f i cat i on)
( capaci t y
i ncr ease)
I t em
#
I t em
#
Why?
What
?
How?
Change i n
pr oper t i e
s
Cor r ect
r ange/
Reasons
Ef f ect
on
qual i t y
Dat e/
Fr equency
Pr obl em
descr i pt i on
( why di d i t
happen?)
Act i on i n
event of
abnor mal i t y
Recur r ence
pr event i on
pr oposal
Li kel y
equi pment / par t
si gns/ phenomen
a
Pr oj ect ed
l oss/ damage
Assess ski l l s.
Set act i on cr i t er i a.
Breakdown!
Abnorm al
noise?
How t o deal wi t h br eakdowns or def ect s t hat have act ual l y t ake
n pl ace?
Breakdown!
To use the experience ofthe
breakdown as a lesson to
im prove the ability to detect
abnorm ality.
Ishould
learn !
It's difficult
to keep the
standards.
I f t he st andar ds have not been r evi sed f or mor e t han hal f a year ,
t hey ar e dead and usel ess
t he l i f e s pan ar e
ng i s i mpos s i bl e t o
s t o under s t and t he
ar s y mpt oms bef or e t he
It is
unusual.
Check by
Operators'
five senses
A little
feverish.
M easuring by
M easurem ent
Tools
Breakage ofthe
piston packing
was revealed.
1300
1334,97
1400
1200
1000
Costi
800
Benefici
600
400
240
241,74
200
0
1
- Costs
Inspection and cleaning activities
Training
- Losses in productivity
Benefits
Further reduction of losses (maintenance
activities) and consequent increase of OEE
Reduction of inspection time through ECRS
method
Reduction of inspection activities made by
professional maintenance team
346
COMBINE
REDUCE
SEMPLIFY Methods
347
AFTER
348
Step 5: results
Costs/Benefits for Step
740
700
2752
2279
2221
1686
1684
2022
1419
1161
2000
Costi
Benefici
583
201
Step 2
Step 3
Step 4
600 600
500
419
Attivit a macchina
ferma
Totale attivit
400
300
280
192,81
200
117,88
100
0
Step 1
Minuti/settimana
4000
Step 5
36
59,19
25
15,00Obj=30 min/sett
% Scraps
2,00
1,80
1,60
1,40
1,20
1,00
0,80
0,60
0,40
0,20
0,00
AM Tags
400
350
286
300
0,42
0,38
307
Step 4
Step 5
238
250
0,40
302
200
0,26
0,18
150
143
100
Step 1
Step 2
Step 3
Step 4
Step 5
Step 1
Step 2 Step 3
349
St ep 6
Activities
Roles
Managers
(fostering
St
ep 6:ofSyst
emat i zeand
autStaff
onomous
mai nt enance
Maj or
2.
3.
4.
5.
f l ow di agr am
Pr oc es s qual i t y as s es s ment
Pr ev ent i v e meas ur es agai ns t
def ec t i v e pr oduc t out f l ow
Pr oduc t handl i ng
Can qual i t y def ec t s be det ec t ed when
t hey oc c ur ?
Maj or
Cleaning is
inspection
St ep 7
Activities
Anal yze
i mpr ove
r el i abi l
qual i t y,
2
1
4 St eps t o Became
a Capabl e Oper at or
Pr act i
ce
f ul l
sel f manage
ment
Syst emat i
6 c
aut onomou
s
Per f or m
5 genermaial nt enan
ce
pr ocess
i nspect
i on al
Conduct
gener
equi pment
i nspect i on
3 Est abl i sh cl eani ng
and checki ng
st andar ds
Addr ess cont ami nat i on
sour c es and
i nacc ess i bl e pl ac es
Per f or m i ni t i al cl eani ng
Recogni z es si gns of
abnor mal i t y ; deal s
wi t h abnor mal i t i es
cor r ect l y; per f or ms
4
per i odi c ov er haul
check i ng and par t s
r epl acement cor r ect l y
Det ec t s abnor mal i t i es
pr ompt l y ; t akes
emer genc y act i on agai ns t
abnor mal i t i es
Under st ands pr oper t i es of
mat er i al s bei ng handl ed;
per f or ms cor r ect adj ust ment
and s et t i ng
5.
At each st ep
NO
Audi t ?
Gr oup act i vi t y
r epor t
Audi t ?
Audi t sheet
NO
Pl ace
st i cker on
equi pment
Poi nt out
pr obl ems
Pr ovi de gui dance
and suppor t
schedul e
Deci de
whet her
gr oup has
Audi t ?
passed st ep
Poi nt out
pr obl ems
Audi t sheet
Gi ve
gui dance and
Gi ve expl anat i on advi
and ce
NO
gui dance
Audi t meet i ng
I ssue pass
st i cker f or st ep
Pass
374
AM Criteria
St ep 1. I ni t i al Cl eani ng
I ni t i al cl eani ng
Wast e, dust and di r t ar e r emoved f r om t he mai n equi pment . The i nsi des of cover s and t he t anks ar e al so cl eaned.
Level 1
(Outside
point) 10%
Inside
30%
50%
Processing
70%
90%
Level 2
(Outside
point) 10%
Inside
30%
50%
Processing
70%
90%
The st r uct ur e and f unct i on of t he equi pment i s t hor oughl y under st ood. Anomal y can be det ect ed cor r ect l y. Oper at or s
have t hor ough t aggi ng ski l l s.
50%
90%
Lev el 4
50%
90%
Lev el 5
(Outside
point) 10%
Inside
30%
50%
Processing
70%
90%
Lev el 1
( I ni t i al cl eani ng
50%
70%
Det 10%
ect i on of di30%f f i cul t ar eas
t o access)
Sour ces
90%
Cover s
70%
90%
For t he spot s di f f i cul t t o car r y out i nspect i on, measur es ar e t aken such as r emovi ng LSs, r eveal i ng pr ocessi ng poi nt s
or i nst al l i ng i nspect i on wi ndows.
(Investigation
10%
Improvement
30%
50%
Easy inspection)
70%
90%
I mpr ovement s f or easy i nspect i on ar e made such as r emovi ng LSs, r eveal i ng pr ocessi ng poi nt s or i nst al l i ng i nspect i on
wi ndows.
(Improvement
10%
Easy cleaning
30%
50%
Easy inspection)
70%
90%
Pr ocessi ng poi nt can be seen even dur i ng oper at i on. No scat t er i ng. Cover s can be r emoved by one- t ouch devi ce and
cl eani ng and i nspect i on can be done easi l y.
( Si mpl e cov er
10%
30%
Based on t he condi t i on t hat cl eani ng and l ubr i cat i ng par t s, met hods, st andar ds and per i ods ar e t empor ar i l y det er mi ned and t hat
st r uct ur e / f unct i on / pr i nci pl es of t he equi pment ar e under st ood, l ubr i cat i on and hydr aul i c syst em char t s ar e pr epar ed.
30%
50%
70%
90%
Level 2
I nspect i on
70%
90%
By r epeat i ng t he i nspect i on based on t he t empor ar y st andar ds, some par t s of i nspect i on i t ems or per i ods needi ng
amendment ar e r eveal ed.
( I nspect i on
Reveal t he i t ems t o be amended,
10%
30%
50%
Make amendment )
I nt ensi ve i t ems
70%
90%
Abnor mal i t i es can be f ound easi l y by usi ng vi sual cont r ol . Equi pment i s i mpr oved i n such a way as t o car r y out easy
i nspect i on wi t hout bendi ng.
(Staring at
10%
Watch carefully
30%
50%
At a glance)
70%
90%
I nspect i on i t ems and i nspect i on per i ods ar e put t oget her . Ef f i ci ent and ef f ect i ve i nspect i on i s car r i ed out wi t hi n 10
mi n. / day ( St andar di zed / ef f i ci ent / ef f ect i ve i nspect i on) .
(Within 30 min.
10%
Within 20 min.
30%
50%
Within 10 min.)
70%
90%
St ep 4. Over al l I nspect i on
I nspect i on based on t he t empor ar y st andar ds
Lev el 1
Based on cl eani ng / l ubr i cat i on / i nspect i on st andar ds, t empor ar y i nspect i on st andar ds ar e made f or each over al l
i nspect i on i t ems ( 6 i t ems) and mi nor def ect i ves ar e r eveal ed.
( I nspect i on
Revi ew / Det er mi nat i on of st andar ds
10%Revel at i on 30%
50%
70%
90%
of def ect i ves)
Ski l l t r ai ni ng by super vi sor s and t eam l eader s
Super vi sor s and t eam l eader s make one- poi nt l essons f or each subj ect by whi ch t r ai ni ng i s car r i ed out t o oper at or s.
Lev el 2
( Make t r ai ni ng mat er i al s
10%
30%
Hor
i zont al expansi
on)
Educat i on & t r ai ni ng
50%
70%
90%
Pr epar e st andar ds
Thr ough r evi ewi ng t empor ar y st andar ds, st andar ds ar e pr epar ed and mi nut e def ec t i s r est or ed and i mpr ov ed.
Lev el 3
( Pr epar at i on of st andar ds
10%
30%
I mpr ovem50%
ent )
Rest or at i on
70%
90%
St ep 4. Over al l I nspect i on
QA condi t i ons
Lev el 4
Consi der i ng t he r el at i onshi p bet ween equi pment and qual i t y, t he opt i mal pr ocessi ng condi t i on i s det er mi ned ( Mai nt ai n
t he cont r ol i t ems of manuf act ur i ng qual i t y and qual i t y st andar ds) .
70%
90%
Smal l r epai r
Smal l r epai r s can be car r i ed out not by mai nt enance per sonnel but by oper at i on hi msel f .
Lev el 5
(Supervisors
10%
Leaders
30%
50%
Operators)
70%
90%
Cl eani ng / l ubr i cat i on / i nspect i on st andar ds ar e r evi ewed i n or der t o pr event t he r ecur r ence of br eakdowns /
def ect i ves / mi nor st oppages / mi s- i nspect i ons.
(Review
10%
recurrence)
Amendment
30%
50%
Zero
70%
90%
Dai l y i nspect i on
Lev el 2
St andar ds ar e r evi ewed. Oper at or s check t hei r equi pment by t hei r 5 senses. Ther ef or e, anomal y can be det ect ed at an
ear l y st age.
( Check by 5 senses
Count er measur es agai nst
10%
30%
70%
90%
Exchange par t s / spar e par t s of t he equi pment ar e managed and t he concer ned peopl e have knowl edge and ski l l s on
exchangi ng par t s and pr event i on of br eakdown.
(Management
10%
Skills
30%
50%
Prevention)
70%
90%
Oper at or s can est i mat e t he per i od of det er i or at i on l i mi t of t he equi pment and can det er mi ne t he det er i or at i on l i mi t
f or each mode.
(Estimate
10%
50%
90%
Lev el 5
(Supervisors
10%
Leaders
30%
50%
Operators)
70%
90%
St ep 6. St andar di zat i on
St andar di zat i on of j i gs and t ool s
Nor mal r epet i t i ve oper at i ons ar e st andar di zed and j i gs and t ool s ar e st andar di zed f or usage i n 5S act i vi t i es.
Lev el 1
(5S
3 normal operations
10%
30%
50%
Standardization)
70%
90%
Mur i ( unnat ur al oper at i on) , Mur a ( i r r egul ar oper at i on) , Muda ( non val ue added oper at i on) ar e gr asped among movement s
i n t he oper at i on, anal yzed, i mpr oved, and oper at i ons ar e st andar di zed.
(Analysis
10%
Standardization)
Improvement
30%
50%
70%
90%
Lev el 3
( Tr ai ni ng of
I mpr ovement
I mpr ovement ski l l s
10%
30%
50%
70%
ar e r ai sed)
90%
act i vi t i es
St ep 6. St andar di zat i on
Saf et y cont r ol
Zer o br eakdown, zer o def ect i ve, zer o mi nor st oppage and zer o acci dent ar e act ual i zed.
Lev el 4
(Zero accident
10%
Zero injury
30%
50%
Zero near-misses)
70%
90%
Shop management
Ther e i s a scheme by whi ch r educt i on of l osses and mai nt enance cost r educt i on ar e cont i nuousl y i n pr ogr ess.
Lev el 5
( Gr as p l oss es
10%
Reduc e c ost
30% i nuous
50%ovem
Cont
i mpr
ent )
70%
90%
Pol i ci es ar e managed by t he act i vi t y boar d and pol i ci es, r esul t s, pr obl ems and t hemes ar e cl ar i f i ed showi ng cont ent s
of act i vi t i es.
(Notice board
board) 10%
Activity board
30%
Utilization
50%
70%
90%
Gr oup meet i ng
Lev el 2
The t r ends of br eakdown l osses, def ect i ve l osses and mi nor st oppage l osses ar e anal yz ed and t he i mpr ovement pl ans ar e
di scussed at gr oup meet i ngs.
30%
Meet i ng
50%
Im
pr ov ement )
70%
90%
The r esul t s and pr obl ems of manuf act ur i ng gr oups ar e known and f ocused i mpr ovement ( PPA, I E met hods,
out act i vel y.
Count er measur es
50%
70%
90%
et c. ) i s car r i ed
Common use of i nf or mat i on i s car r i ed out at i mpr ovement case st udy meet i ngs and / or gr oup wor kshops. I mpr ovement abi l i t y at
t he wor kshop i s i mpr oved.
90%
Oper at or s can t ake car e of mai nt enance act i vi t i es agai nst def ect i ves and br eakdowns, such as r est or i ng and i mpr ovement
act i vi t i es.
Speci al mai nt enance per sonnel ar e engaged i n devel opi ng mor e advanced mai nt enance .
( Smal l r epai r
10%
Mai nt enance t r ai ni ng
30%
50%
Mai nt enance)
70%
90%
TABLE
TABLE
Step 1
No.
1.
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
Sheet 1 of 5
Audit points
Results
TABLE (-Continued)
Step 1
1.11
1.12
1.13
1.14
1.15
1.16
1.17
1.18
1.19
1.20
Sheet 2 of 5
TABLE (-Continued)
Step 1
2
2.1
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Sheet 3 of 5
TABLE
Step 1
2.2
(1)
(2)
(3)
(4)
2.3
2.4
2.5
2.6
2.7
2.8
2.9
(-Continued)
Sheet 4 of 5
TABLE (-Continued)
Step 1
3.
3.1
3.2
3.3
3.4
4.
4.1
5.
5.1
Lubrication
No dirt, dust or leakage in and around air lubricators, oil
reservoirs or centralized systems?
Is oil level proper? Adequate lubricants at lubricating
surfaces?
No contamination at lubricating points and surfaces?
Are lubricants not contaminated? Not deteriorated?
Short remedial program
Is outline of short remedial program known?
Residual issues
No residual questions, equipment defects? If so, do
reasonable explanations exist? Are plans and schedules to
solve these issues clear?
Sheet 5 of 5
TABLE
Step 2
No.
1.
1.1
1.2
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
Sheet 1 of 6
Audit points
Results
Step 1 conditions
Is cleanliness attained in Step 1 well maintained?
Are residual issues left over from Step 1 resolved?
Group activity (General)
Are aims of Step 2 understood adequately?
Is activity plan made in advance? Well executed?
Are managers models well understood?
Is activity board adequately utilized?
Are defective areas accurately located? Confirmed by all
members?
No overlooked defective areas detectable with current
knowledge?
Are identification tags collected and kept after remedies?
Are questions sufficiently posed?
Are questions definitely resolved? Understood by all
members?
TABLE (-Continued)
Step 2
2.10
(1)
(2)
(3)
(4)
2.11
2.12
2.13
2.14
2.15
2.16
2.17
2.18
2.19
Sheet 2 of 6
TABLE (-Continued)
Step 2
3.
3.1
3.2
3.3
3.4
3.5
3.6
Sheet 3 of 6
Sources of contamination
Are remedial actions taken deliberately, based on detailed
assessment of actual generating conditions of contaminants?
Are locations and manners of contaminants clearly recognized
by detailed observation? Where-where analysis conducted, if
necessary?
Are structure and function of equipment sufficiently learned?
Why-why analysis conducted, if necessary?
Are all simple sources resulting from deteriorated parts such
as water, oil and stream leakage remedied?
Are cost and effects of remedies reviewed? Actual figures
recorded?
Difficult cleaning area
Are remedial actions taken deliberately, based on detailed
assessment of actual conditions of cleaning tasks in awkward
work areas?
Are sources thoroughly remedied to make actions against
difficult cleaning areas unnecessary?
Are costs and effects of remedies reviewed? Actual figures
recorded?
TABLE (-Continued)
Step 2
6.
6.1
6.2
6.3
6.4
6.5
6.6
7.
7.1
7.2
7.3
Sheet 5 of 6
TABLE (-Continued)
Step 2
8.
8.1
8.2
9.
9.1
9.2
9.3
9.4
9.5
10.
10.1
10.2
Visual control
Are visual controls devised to facilitate cleaning tasks?
Are available visual controls installed using current technical
knowledge and skill?
Short remedial program
Is subject selected from the six big losses?
Are problems clearly identified? Targets pinpointed?
No easy countermeasures taken?
Are cost and effects of program reviewed? Actual figures
recorded?
Are preventive measures against recurrence of problems
provided?
Residual issues
No residual questions, equipment defects? Are secure plans
and schedules for corrective actions prepared?
No residual remedies against sources of contamination and
difficult cleaning areas? If so, do reasonable explanations
exist? Are plans and schedules to solve these issues clear?
Sheet 6 of 6
TABLE
Step 3
No.
1.
1.1
1.2
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
Sheet 1 of 7
Audit points
Results
Step 2 conditions
Is cleanliness attained in Step 2 well maintained?
Cleaning standards definitely observed?
Are residual issues left over from Step 2 resolved?
Group activity (General)
Are aims of Step 3 understood adequately?
Is activity plan made in advance? Well executed?
Are managers models well understood?
Is TPM activity board adequately utilized?
Are safety matters carefully respected?
Are TPM activity hours and frequency adequate?
Is more efficient way of TPM activity pursued?
Are used spare parts and consumables recorded?
TABLE (-Continued)
Step 3
No.
2.9
2.10
2.11
2.12
2.13
3.
3.1
3.2
3.3
Sheet 2 of 7
Audit points
Results
TABLE
Step 3
No.
3.4
(1)
(2)
(3)
(4)
4.
4.1
4.2
4.3
4.4
4.5
4.6
(-Continued)
Sheet 3 of 7
Audit points
Results
TABLE (-Continued)
Step 3
No.
5.
5.1
5.2
5.3
5.4
5.5
Sheet 4 of 7
Audit points
Results
TABLE (-Continued)
Step 3
No.
6.
6.1
6.2
6.3
7.
7.1
7.2
7.3
Sheet 5 of 7
Audit points
Results
Cleaning/lubricating standards
Are cleaning/lubricating standards comprised of systematic
combinations of tentative cleaning standards set in Step 2 and
lubricating standards set in Step 3?
Can everyone locate any defects relating to basic equipment
conditions?
Can everyone clean and lubricate in accordance with
standards? Time target achieved? If not, are adequate plans
and schedules prepared?
Equipment (Main body and surroundings)
Are tools and jigs stored at designated locations? No shortage
or damage?
No unnecessary pieces or equipment?
No unnecessary materials in process? No dropped parts on
floor?
TABLE (-Continued)
Step 3
No.
7.4
7.5
7.6
8
8.1
8.2
9.
9.1
9.2
Sheet 6 of 7
Audit points
Results
TABLE (-Continued)
Step 3
No.
9.3
9.4
9.5
10.
10.1
10.2
Sheet 7 of 7
Audit points
Results
TABLE
Step 4
No.
1.
1.1
1.2
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
Sheet 1 of 10
Audit points
Results
Step 3 conditions
Are the basic equipment conditions attained in Step 3 well
maintained? Cleaning/lubricating standards definitely
observed?
Are residual issues left over from Step 2 or previous sub step
resolved?
Group activity (General)
Are aims of Step 4 understood adequately?
Is activity plan made in advance? Well executed?
Are managers models well understood?
Is activity board adequately utilized?
Are safety matters carefully respected?
Are TPM activity hours and frequency adequate?
Is more efficient way of TPM activity pursued?
Are used spare parts and consumables recorded?
TABLE (-Continued)
Step 4
No.
2.9
2.10
2.11
2.12
2.13
3.
3.1
3.2
3.3
Sheet 2 of 10
Audit points
Results
TABLE (-Continued)
Step 4
No.
3.4
4.
5.
5.1
5.2
5.3
5.4
5.5
Sheet 3 of 10
Audit points
Results
TABLE (-Continued)
Step 4
No.
5.6
5.7
6.
6.1
6.2
6.3
6.4
6.5
6.6
Sheet 4 of 10
Audit points
Results
TABLE (-Continued)
Step 4
No.
7.
7.1
7.2
8.
8.1
8.2
8.3
8.4
8.5
Sheet 5 of 10
Audit points
Results
Visual control
Are visual controls thoroughly applied to facilitate inspecting
tasks?
Are new visual controls devised? Noteworthy ideas actively
revealed to other PM groups?
Short remedial program
Is subject selected from the six big loses?
Are problems clearly identified? Targets pinpointed?
No easy countermeasures taken?
Are cost and effects of program reviewed? Actual figures
recorded?
Are preventive measures against recurrence of problems
provided?
TABLE (-Continued)
Step 4
No.
9.
9.1
9.2
Sheet 6 of 10
Audit points
Results
Residual issues
No residual questions, equipment defects? Are secure plans
and schedules for corrective actions prepared?
No residual remedies against difficult inspecting areas?
If so, do reasonable explanations exist? Are plans and
schedules to solve these issues clear?
TABLE (-Continued)
Step 4
No.
4.
4.1
4.2
4.3
4.4
4.5
4.6
Sheet 7 of 10
Audit points
Results
TABLE (-Continued)
Step 4
No.
4.
4.1
4.2
4.3
4.4
4.5
Sheet 8 of 10
Audit points
Results
TABLE (-Continued)
Step 4
No.
4.6
4.7
4.8
4.
4.1
4.2
4.3
4.4
4.5
4.6
4.7
Sheet 9 of 10
Audit points
Results
TABLE (-Continued)
Step 4
No.
4.
4.1
4.2
4.3
4.4
4.5
4.6
4.7
Sheet 10 of 10
Audit points
Results
TABLE
Step 5
No.
1.
1.1
1.2
1.3
1.4
1.5
2.
2.1
2.2
2.3
2.4
2.5
Sheet 1 of 6
Audit points
Results
TABLE (-Continued)
Step 5
No.
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
3.
3.1
Sheet 2 of 6
Audit points
Results
TABLE (-Continued)
Step 5
No.
3.2
3.3
3.4
3.5
3.6
Sheet 3 of 6
Audit points
Results
TABLE (-Continued)
Step 5
No.
3.7
3.8
3.9
3.10
4.
4.1
4.2
4.3
Sheet 4 of 6
Audit points
Results
TABLE (-Continued)
Step 5
No.
4.4
4.5
4.6
5.
5.1
5.2
6.
6.1
6.2
6.3
6.4
6.5
Sheet 5 of 6
Audit points
Results
TABLE (-Continued)
Step 5
No.
6.6
7.
7.1
Sheet 6 of 6
Audit points
Results
TABLE
TABLE
Step 6
No.
1.
1.1
1.2
1.3
2.
2.1
2.2
2.3
2.4
2.5
Sheet 1 of 8
Audit points
Results
Step 5 condition
Are all equipment-related problems solved? No residual
issues?
Is operators routine maintenance definitely executed in
accordance with autonomous maintenance standards and
schedules?
Are cause analysis and preventive measures taken in each
event of breakdowns or minor stoppages occurring in spite of
secure observation of autonomous maintenance standards?
Assistance of full-time maintenance satisfactory?
Group activity (General)
Are aims of Step 6 understood adequately?
Is activity plan made in advance? Well executed?
Are managers models well understood?
Is activity board adequately utilized?
Are safety matters carefully respected?
TABLE (-Continued)
Step 6
No.
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
3.
4.
4.1
Sheet 2 of 8
Audit points
Results
TABLE (-Continued)
Step 6
No.
4.2
5.
5.1
6.
6.1
6.2
6.3
6.4
6.5
Sheet 3 of 8
Audit points
Results
TABLE (-Continued)
Step 6
No.
3.
3.1
3.2
3.3
3.4
(1)
(2)
(3)
Sheet 4 of 8
Audit points
Results
Step 6-1-1
Are process quality and tolerances clearly identified at each
exit of equipment? Quality assurance flow diagram(QAFD)
drawn?
Are process quality assurance lists prepared by reviewing
quality-related modifications carried out in the past steps in
terms of equipment, work methods, quality control standards,
visual controls and mistake proofs?
Are quality assurance flow diagrams revised whenever quality
related modifications of equipment or work methods take
place?
Process quality and relevant inspecting items in terms of
initial, interim and final product:
Clearly defined? Absolutely needed?
Well understood?
Easy to understand?
TABLE (-Continued)
Step 6
No.
3.
3.1
(1)
(2)
(3)
3.2
3.3
Sheet 5 of 8
Audit points
Results
Step 6-1-2
Quality standards, inspecting items and criteria, and corrective
actions to be taken when problems occur in terms of initial,
interim and final product:
Well observed?
Easy to understood?
Can deviation be detected at a glance when problems occur?
Can everyone accurately and promptly inform relevant
departments when quality defects occur?
Are quality standards, inspecting item and criteria corrective
actions, visual controls and mistake proofs sufficiently
improved?
TABLE (-Continued)
Step 6
No.
3.4
3.
3.1
3.2
(1)
(2)
(3)
(4)
(5)
Sheet 6 of 8
Audit points
Results
TABLE (-Continued)
Step 6
No.
3.3
3.4
3.5
3.
3.1
3.2
(1)
(2)
(3)
(4)
(5)
Sheet 7 of 8
Audit points
Results
TABLE (-Continued)
Step 6
No.
3.3
3.4
3.5
3.
3.1
3.2
3.3
3.4
Sheet 8 of 8
Audit points
Results
It shows the
history ofthe
activities very
well.
This is the
realactivity
bulletin board.
M ethods
Norm al
operation
Daily
m aintenance
M aintenance
activities
Activities
Prevent
Deterioration
M easure
Deterioration
Allocation
Restore
Equipm ent
Proper operation
Setup/adjustm ent
CleaningDetecting and
correcting hidden faults
Lubrication
Conditions ofuse,daily
deterioration check
M inor servicing
Periodic
m aintenance
O perators M aintenance
Periodic inspection
Periodic testing
Periodic servicing
Overallequipm ent
effectiveness at
least 85%
Breakdown
m aintenance
Im proving
reliability
Im provem ent
activities
Trend testing
Im provem ent
activities
Repair breakdowns
Strengthen
Reduce load
Increase precision
Im proving
m aintainability
Non-routine servicing
436
One-Point Lesson
Theme: V-belt
1.
Basic Knowledge
2.
3.
1.
2.
Do not i gnor e ver t i cal shaki ng of VAdj us t t ens i on and c ent er of pul l ey
ver t i cal shaki ng i s
caused by
cent er f r i ct i on
l ooseni ng
f r i ct i on
Reference #
437
One-Point Lesson
Theme: Ai r Cl ut c h: St r uc t ur ed Di agr am
and Oper at i on
1.
Basic Knowledge
2.
3.
Oper at i on
At t ached t o t he cl ut ch housi ng
( 10) secur ed t o t he f l ywheel
ar e a pr essur e di sk ( 4)
[ suppor t ed by a gui de key ( 3) ] ,
a di aphr agm ( 6) and a r ot ar y
connect i on ( 9) , et c.
When t he sl i de r eaches t he
upper dead poi nt , t he ai r shut s
Reference # of f and escapes f r om t he
di aphr agm. A r et ur n spr i ng
causes t he pr essur e di sk t o
438
One-Point Lesson
Theme: Ai r Cl ut c h: Fai l ur es and
Mal f unc t i ons I ns pec t i on Poi nt s
Phenomenon
1. Sl ow dr i ve
shaf t r ot at i on
( sl i ppi ng)
2. Rot at i on not
t r ansmi t t ed
Cause
Measur es
1. Wor n scr at ched 1. Repl ace l i ni ng
br ake f aci ng
2. I nvent or y and
2. Dr op i n ai r
r epai r ai r l eaks
pr essur e
1. No ai r comi ng
1. I nvent or y and
r epai r
2. Br oken
el ect r i cal
di aphr agm
f ai l ur es
1. Bear i ngs out
of oi l , wor n
or damaged
2. Spl i ne wear
4. Vi br at i on
5. Heat
Written by:
Location:
2. Repl ace
1. Check oi l ;
r epl ace
2. Repai r or
r epl ace
1.
Basic Knowledge
2.
3.
439
One-Point Lesson
Theme: How t o Mar k Nut s and Bol t s
1.
Basic Knowledge
2.
3.
Written by:
Location:
Reference #
440
One-Point Lesson
Theme: Pneumat i c Dev i c es : Ai r Fi l t er
1.
Basic Knowledge
2.
3.
St r uct ur al Di agr am
5. Et c.
Written by:
Location:
Reference #
441
One-Point Lesson
Theme: Ai r Fi l t er : Fai l ur es and
Mal f unc t i ons
Phenomenon
1. Cont ami nant s come
out of OUT por t
3. Excessi ve dr op i n
pr essur e
5. Damaged bowl
Written by:
Location:
1.
Basic Knowledge
2.
3.
Cause
Measur es
1- 1 Negl ect ed
cont ami nant
r emoval
1- 2 Fl ow t hr ough
f i l t er exceeds
pr escr i bed vol ume
2- 1 Poor O- r i ng ( 5)
seal
2- 2 Bad dr ai n val ve
( 9)
3- 1 Fi l t er el ement
( 2) cl ogged
3- 2 I mper f ect el ement
( 2) seal
4- 1 Damaged f i l t er
el ement
4- 2 I mper f ect seal
el ement
5- 1 Used i n
at mospher e
Reference #
cont ai ni ng an
or gani c sol vent
442
One-Point Lesson
Theme: Fi l t er
1.
Basic Knowledge
2.
3.
Fi l t er
Fi l t er OK
I ndi cat or
down
Written by:
Location:
Fi l t er
Cl ogged
I ndi cat or
in
up
posi t i on
Reference #
443
One-Point Lesson
Theme: Your Tool s and How t o Us e Them
1.
Basic Knowledge
2.
3.
St r uct ur e
Hand Oi l er
Basi c
Funct i ons
Pr oper
Handl i ng
Nozzl e- capped
pol yet hyl ene
cont ai ner
Pl ace t i p of
nozzl e f aci ng
down at oi l i ng
si t e and pr essOt her exampl es:
Oi l can
l i ght l y on
Oi l can
cont ai ner
Funnel
Pump oi l can
Pi st ol - t ype oi l er
Do
not
cr
ush
Al l used f or
Written by:
Location:
Reference #
444
One-Point Lesson
Theme: I mpr ov ement of Unr eadabl e Oi l
Lev el Gauge on Br ak e
1.
Basic Knowledge
2.
3.
Current Situation
The oi l gauges on a conveyor br ake and a gear
mot or
l
can t be checked because t hey ar e
hi dden behi nd pul l eys
l
ar e di scol or ed and cl oudy
Spar es ar e di f f i cul t t o get and har d t o
i nst al l , so t he gauges ar en t checked and
l ubr i cat i on i s l ef t unmanaged.
Description of Improvement
We at t ached a commer ci al l y avai l abl e oi l gauge
t o a shor t pi pe i nser t ed i n t he dr ai n hol e.
Thi s made i t easy t o check t he oi l l evel .
ol d
oi l
gaug
e
oi l
dr a
gauge i n
hol
e
i mpr oved oi l gauge
ni ppl e
T
bl i nd val ve ( dr ai n
hol e) and cl eani ng
hol e
shor t pi pe ( l ong
enough t o r each
dr ai nage cont ai ner )
Reference #
445
One-Point Lesson
Theme: I s t he hy dr aul i c uni t wor k i ng
nor mal l y ? ( par t 2)
If
af t
1,
But
2.
n sl ow at l ow t
hydr aul i c uni t
t he next l evel
i ons t o ask bef
1.
Basic Knowledge
2.
3.
emper at ur es even
as descr i bed i n Par t
of count er measur es.
or e you do:
Reference #
446
One-Point Lesson
Theme: An Ex ampl e of Res t or at i on
1.
Basic Knowledge
2.
3.
Cycl e di agr am
An Exampl e of Rest or at i on
Pr obl em
Tr eat ment
The
mi cr oadj ust m
ent of t he
val ve t hat
adj ust s t he
f i ni sh f eed
speed di dn t
wor k.
The cam pl at e
had devel oped
r i dges, and
t he val ve
coul d not
adj ust t he
f l ow
cor r ect l y.
We r epl aced
t he cam
pl ati se.
Ther e was debr
adher i ng t o t he t i p of
t he speed cont r ol
val ve.
The l oadi ng
speed was
sl ow and t he
nongr i ndi ng
per i ods wer e
t oo l ong.
Written by:
Location:
Reference #
We t ook t he val ve
apar t and cl eaned
it.
447
Di r t & Gr i me
Rust
Machi ne i n
oper at i on
( wi t h cut t i ng
Rubbed- of f par t i cl es
debr i s, sand,
Vi br at i onet c. )
I ce f or mat i on
Oi l oxi des
Ai r
Pai nt
448
Vane pump
( vane si des)
5 13
Val ve
( spool &
sl eeve)
1 23
Gear box
( gear wheel & 0. 5 5
si de pl at e)
449
One-Point Lesson
Theme: How t o adj us t ai r pr es s ur e on t he Fy c on Fi ni s h
Appl i c at or
det ai l of
pr essur e gauge on
r egul at or
If
pai
If
pai
t he pr ocess i
nt ed sect i on
t he pr ocess i
nt ed sect i on
s
of
s
of
450
Grease Fittings
1.
2.
3.
451
1. Wr i t e
your
name
2.
Recor d
t he
dat e
Name: Tom F. Date: 8/21/99
Item: Electric Drill
3.
Recor d
l ocat i on
of f ound
i t em
Location of Item:
Door Assembly Area Floor
Reason for Red Tagging:
Broken handle
Suggested Disposition:
Discard, not fixable
4.
Recor d
r eason
f or
t aggi ng
5. Make
suggest i o
n f or
r esol ut i o
n
u
u
452
One-Point Lesson
Theme: The Two- Bi n Sy s t em f or I ns t ant
Mai nt enanc e Par t s
1.
Basic Knowledge
2.
3.
Par t # 2008010018- 0
Name: Gui de pi n
Or der quant i t y :
50 uni t s
When t he
or der ed par t s
ar r i ve, put
t hem i n si de A
Cont i nue t o r epeat st eps
Written by:
Location:
and
Reference #
453
One-Point Lesson
Theme: Hy dr aul i c Power Uni t
I ns pec t i on
1.
Basic Knowledge
2.
3.
The hydr aul i c power uni t pr ovi des power t o t he ent i r e hydr aul i c syst em. Even
i f you use t he r i ght amount of oi l , l ocal oi l shor t ages, cl ogged f i l t er s, or
ot her causes may r esul t i n cavi t at i on. *
Thi s can cause pr obl ems ( noi se, cor r osi on, pr essur e f l uct uat i ons, or
vi br at i on) i n hydr aul i c devi ces t hr oughout t he syst em, so dai l y checks ar e
W
hat t o Check and How
essent i al .
Dai l y checks can be per f or med dur i ng oper at i on and consi st of l ooki ng f or
abnor mal i t i es usi ng t emper at ur e and ot her gauges, as wel l as t he human
senses of si ght , hear i ng and t ouch.
pr essur
Bad Exampl e
e gauge
1.
mot or
oi l
r et u
pump r n
oi l
l evel
gauge
suct i on f i l t er
454
Good Exampl e
pr ess ur
e gauge
oi l
r et u
rn
mot or
Written by:
bar r i er
pump
* When a l ocal dr op i n oi l
pr essur e occur s, di ssol ved ai r
escapes i n t he f or m of bubbl es.
When r api d pr essur e i s t hen
appl i ed, t he ai r has no t i me t o
r edi ssol ve and t he ai r becomes
super compr essed and causes noi se
as i t st r i kes a sur f ace. Thi s i s
cal l ed cavi t at i on.
Reference #
Location:
455