JH

Concept St
JIPM-S
2007/08
Takashi Sagae
 Concepts of Step-by-Step Implementation of Autonomous Maintenance

Change
Changeininthe
the
way of thinking
way of thinking
Step 0 Step 1,2,3 Step6 & 7
Step 4& 5
(Preparation) Defects
Defectsand
and Effects
failures are Effects
failures are Zero
Effects shame
Effects People shameofof Zero
Work
Motivation
Change
Change Defects People workshop defects Worksite
site
Motivation Defects change workshop defects change
equipment
equipment change change
and
and and
andzero
zero
failures Change failures
failures Changeinin failures
reduced activity
activity achieved
reduced achieved
Think and act Restore abnormality Positive
Positive
improvement
improvement
activities
activities
Source of motive is Cleaning is inspection Thorough
Inspection means finding malfunctions Thorough
present in the implementation
process of behavior Malfunctions must be rectified and implementation
improved ofofmaintenance
maintenance Bottom up from circles
and
andcontrol
control Operators consider
problems required to solve
Have operators Restoration and by themselves
consider why forced Have operators consider
deterioration occurs why forced deterioration improvement are
and why occurs and why
autonomous autonomous maintenance
accomplishments
maintenance is is required now Results are the joy of
required now
achievement
Step for operators skill enhancement in
equipment operation and maintenance
4 stage for operators skill
7 step of JH Enhancement
Complete autonomous
management

Standardization
Autonomous inspection

General inspection
Preparation of tentative
standard for JH
Countermeasures for
contamination sources and hard-
to-access areas
Initial cleaning
 Example of Autonomous Maintenance Implementation Steps
Step Description Details of activities
Completely remove dust and dirt on and around equipment,
Initial cleaning
1 (Cleaning inspection)
implement lubrication and retightening, and detect and rectify
abnormalities in equipment.
Measures against sources Take measures against sources of dust and dirt, prevent scattering,
2 of problems and difficult improve areas difficult to clean, lubricate and inspect, and shorten
areas time required for them.
Establishment of a Establish an activity standard to reliably maintain cleaning,
3 tentative standard for lubrication, retightening, and inspection in a short period of time.
autonomous maintenance (It is necessary to indicate daily or periodic timeframe available.)
Provide education about inspection skills based on inspection
General inspection
4 Education
manuals and detect and rectify minor defects in equipment through
overall inspection.
Establish cleaning, lubrication and inspection standards that can be
5 Autonomous inspection maintained reliably and efficiently, and prepare autonomous
management check sheet and put it into practice.
Standardize various kinds of filed management items and
completely systematize maintenance control.
Field distribution standard
6 Standardization
Standardization of data and record
Die, jig and tool management standard
Process quality assurance standard, etc.
Implement corporate policy and targets, routinize improvement activities,
Thorough implementation of
7 autonomous management
keep a records of MTBF analysis, and improve equipment based on the
analysis.
 Step 4: General Inspection Education
[Purpose] (1) Understand the structure, functions, principle and optimum state of equipment
(2) Acquire skills to inspect main functions and components of equipment
(3) Inspect every main functional component and expose and rectify latent defects
Prepare Provide training
Pick out subjects Instructor
Cut model
Prepare teaching materials
Inspection item list Make out a schedule for Leader
Flowchart education and training 6 subjects by mechanical element plus 2 subjects
System diagram

Implement overall inspection Prepare one-point

Education Spread of
Training education

3. Hydraulics

8. Processing conditions
Overall inspection

1. Bolts and nuts

manual
Permanent

2. Lubrication

4. Pneumatics

6. Electricity
fix of Inspection
Check of degree

7. Safety
effects

5. Drive
of understanding

Rectification and
improvement Prepare a temporary inspection standard for each subject Skill check

Visible control
Self-diagnosis by subject
TPM activities board Circle activity
Finding

report
See data of each subject
Plant management diagnosis by subject
abnormality
Hydraulic

Application for
plant audit
Pass
 Step 4: Implementation Procedure
Pick out overall inspection subjects Bolts and nuts, lubrication,
pneumatics, hydraulics, drive,
Maintenance staff
electricity, equipment safety,
and processing conditions
overall inspection
Preparation for

training about
education and

Prepare teaching materials for education and training

about overall inspection
Maintenance staff
Overall inspection check sheet

Make out a schedule of education and Overall inspection manual

training about overall inspection
Maintenance staff Foreman
Cut model map,

To next overall inspection

subject (Two-month cycle
slides, etc.
Provide education to circle leaders
Implementation of

per subject)
overall inspection

Maintenance staff
training about
education and

Prepare for spreading education to circle

members
Circle leader Foreman

Spread education to circle members

(Overall inspection of model machine)

Circle leader
 Step 4: Implementation Procedure
Implement overall inspection (Overall inspection of all machines)

Implementation of
overall inspection
Circle member

List abnormalities and plan

countermeasures at circle meetings Overall
Circle member inspection check
sheet
Improve abnormal items Deteriorated point

Circle member Maintenance department personnel

Area difficult to inspect

Establish temporary standard for daily

inspection Temporary
Circle member standard
Permanent fix of each

(Establish for each subject)

overall inspection

Check inspection skill

subject

Circle leader Skill check list

Implement self-diagnosis and apply for (Have operators

audit receive tests)
Circle leader

Receive diagnosis
Maintenance staff
Foreman

Take corrective action for findings

 Hydraulic System
Hydraulic system flowchart

Pressure control valve

Hydraulic pump
Hydraulic tank

Actuator
motor

Pipe
Hydraulic system diagram

(2) (6)
(3)

(5)

(1) (4)
 Pneumatic source
system

Filter

Pneumatic system diagram

Pneumatic system flowchart

Pressure control valve

Oil control valve

Pipe and fitting

Directional control
valve
Pneumatic System

Flow control valve

Actuator
 Individual Improvement in Circle Activities
Autonomous maintenance

Step 0 Step1-3 Step4-5 Step6-7

Fulfillment Maintenance
Inspection
of basic and control
conditions

Preparation

Individual improvement
 Ex.Hydraulic Education

The
The essence
essence of
of hydraulic
hydraulic

Hydraulic pressure occurs at first by

shutting in liquid,
And pressure is decided by power of load
(external force).
 Seven items to learn when I
understand hydraulic pressure
1.
1. A
A difference
difference ofof pressure
pressure and
and power
power
2.
2. Difference
Difference pressure
pressure
3.
3. Three
Three lines
lines
4.
4. Connection
Connection of of aa line
line
5.
5. Valve
Valve
6.
6. Restrictor
Restrictor
7.
7. Machinery
Machinery
 1.
1. A
A difference
difference of
of pressure
pressure and
and power
power

Power = Pressure Area

Even
Even ifif pressure
pressure isis high,
high, power
power may
may not
not
be
be strong.
strong.
(Power
(Power of of aa spring)
spring)

10kgf/cm^2 <?> 100kgf/cm^2

Hydraulic Power=Pressure Area Spring Power

 2. Difference pressure

When liquid flows, difference pressure acts.

When water of a river flows, there is difference pressure.

When liquid does not flow, there is not difference pressure.

Because there is not difference pressure,

water of a pond does not flow

P1 difference pressure
difference pressure P
P P1 P2
P2
 3. Three lines

Main Line
Move a cylinder of a device.

Pilot Line
A control circuit

Drain Line
A drain circuit.
 4. Connection of a line

Separation.

Connection
 5. Valve

Separation.

Connection
 6. Restrictor

Fixation

Variation
 7. Machinery

A Part
 An
An education
education method
method
Repeat a student with a teacher in turn.

.
A
A machine
machine for
for education
education training
training
Hydraulic
Hydraulic for
for education
education training(1)
training(1)

A change of
pressure by
color coating
Hydraulic
Hydraulic for
for education
education training(2)
training(2)
Hydraulic
Hydraulic for
for education
education training(3)
training(3)

Study how to
read circuit by
color coating
Hydraulic
Hydraulic for
for education
education training(4)
training(4)
Other
Other aa machine
machine for
for education
education training
training
 STAGE 1

PREPARATION
Unilever Ex.
 Equipment / Team / Responsibilities

TEAM
1) A.N.PATIL - ENGG. OFFICER
3) H. GUPTA - PROD. OFFICER
5) S.BUKKAWAR - Sr. TECHNICIAN
7) R.MALVE - TRAINEE TECHNICIAN
2) T. JOSHI - ENGG. OFFICER
4) R.MADEWAR - PROD.OFFICER
6) S.DAKHORE - TECHNICIAN
 Overall Master Plan For Jishu Hozen Step 4
2000 2001
CIRCLE LEADER EQUIPMENT
DQ JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC

SPANDAN KHADE HASSIA-2

BUNIYAD SYED HASSIA-4

DISCOVARY SYED FLEX- 1 & 2

DOLPHIN KHADE GAB 2

SANGAM PATIL GAN

FRIENDS JOSHI BOTTLING - 3

FRIENDS JOSHI BOTTLING - 4

FRIENDS JOSHI OIL FILTER

UTSAHIT GOHOKAR FRYMA MIXER

UTSAHIT GOHOKAR GANSON MIXER

UTSAHIT GOHOKAR DOPP MIXER 1&2

UTSAHIT GOHOKAR THOMPSON

PRABHAT PATIL UNIVERSAL MIXER

TWINKLE JOSHI CODING MACHINE

GENIUS HEMANT FLEX 3 & 4

BUNIYAD SYED HASSIA-1

PRABHAT PATIL BOILER

PRABHAT PATIL COMPRESSOR 2

 MASTER PLAN - JH STEP 4
2000 2001
NO. Activities
Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

1 Identification of subject

2 Preparation of training material

Working out schedule for Education and

3
training

Education and training to the Circle

4
leaders/circle members

5 Implementation of Overall Inspection

6 Preparation of list of minor defects

7 Improvements on minor defects items

Preparation of tentative routine

8
inspection standards

9 Checking inspection skills

10 Audit

11 Roll out on Other machines

 SUBJECTS FOR GENERAL INSPECTION

DRIVE
SAFETY
TRANSMISSION

PNEUMATIC
FASTENERS
SYSTEM

AUTONOMOUS
MAINTENANACE
HYDRAULIC LUBRICATION
SYSTEM SYSTEM

ELECTRICAL PROCESSING
SYSTEM CONDITIONS
 Identification of Subjects

GAN TUBE FILLING MACHINE

Fasteners Drive s Pneumatics Electrical Lubrication Safety

Bearings Air Grease Safety

Bolts & Main power
and pressure Nipple Earthing
Screws supply
Bushes supply

Pulley and Induction Grease Safety

Nuts Filters Gun Guards
belt motor

Cam and Pressure Safety

Washers cam control Relays Oil Can
Switches
followers valve

Keys and Sprockets Pneumatic

Contactor Oil Grades
Keyways and chains cylinder

Grub Proximity
Springs
screws switches

Studs Shafts Photocell

Proximity
Circlip Gears
Switches

Clutch and
brakes
 ! "
# $ 0
% & ' 1+1
02 3
( ) 1
*
" +,- +,.
/
4
" 5
" +
!
#
 MASTER PLAN - JH STEP 4 -- Subjects

2000 2001
NO. Subjects
Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

1 Nuts and bolts

2 Drive system

3 Pneumatics

4 Electrical system

5 Lubrication system
 TRAINING & EDUCATION MATERIAL

SYSTEM
MANUALS
DIAGRAMS

OPLs FLOW
CHARTS

TRAINING
GENERAL
AIDS
INSPECTION CUTAWAY
SHEETS MODELS

VIDEO WORKING
TAPES / VCDs MODELS
 Flow Diagram of Drive System
Tube Tube Tilter Photocell Piston Rotary Rack rod Photocell
Ejector Pressing Cutoff Valve Filling Tube Lifter

4 5 6 7 8 14 9 10 11 12 13
G
e
Cam Cam Cam Cam Cam a Cam Cam Cam Cam Cam
r
G G
Chain Drive e e
a a
S 3 r r 15 Tube Align Tube Lift
Cone Filling

G
e Indexing
Chain Drive a
r Unit
2 Idler 16
18 17
Belt Drive M - Motor
1 GB - Gear Box
GB M S - Sprockets
 Schematic Diagram of Drive System
Reverse Lock Mechanism

Chain Driving Shaft

Chain Tightner (Idler)

Gear Box Motor
 Overall Inspection, Jishu Hozen Step - 4
Machine - Capping Machine Section - Bottle Infeed Prepared by: Sunder Mahajan /Jayesh lad 01.01.01

NO. 1 2 3 4 5 6 7 8 9 10 11 12 13

DRIVE SPROCKET

IDLER SPROCKET
DRIVEN BEVEL

WORM SHAFT
DRIVEN SPUR
DRIVE BEVEL

DRIVE SPUR

IDLER SPUR
SPROCKET
DRIVEN
CHAIN
SHAFT

SHAFT

SHAFT
GEAR

GEAR

GEAR

GEAR
GEAR
FLOW CHART

COMP. NO. 1 2 3 4 5
QTY. (Nos.) 1 1 1 1 1 1 1 1 1 1 1 1 1

SYSTEM
CHART Main
Parts

Sub
Com ponent

Nam e Key Key Bearing Key Hex. Pin Links Holder Bearing Key G.M.Bush Key Bearing Hex. Bolt
Qty. (Nos.) 1 1 2 1 1 1 2 1 1 1 2 1
Sub
Com ponent
Nam e GrubScrew GrubScrew Hex. Bolt GrubScrew Hex. Bolt Lock Key Hex. Bolt Shaft Hex. Bolt Washer
Qty. (Nos.) 1 1 3 1 1 1 1 4 1 4 1
Sub
Com ponent
Nam e Hex. Nut GrubScrew Washer Washer G.M.Bush
Qty. (Nos.) 1 1 4 4 1
Sub
Com ponent
Nam e Washer Lock Pin Bracket
Qty. (Nos.) 1 1 1
 Overall Inspection Items of Drive System

1) Mechanical Drive Motor -

1.1 Abnormal sound and vibration.
1.2 Motor shaft alignment to pulleys
1.3 Perpendicularity of motor mount base
1.4 Vibration and excessive heat up of bearing
2) V Belt and Pulley -
2.1 Uneven wear of belt
2.2 Belt tension
2.3 Pulley groove surface.
2.4 Alignment of two pulleys.
3) Reduction Gear Box-
3.1 Lubricating oil volume
3.2 Abnormal sound and vibration,
3.3 Abnormal Heat up
3.4 Chatter of input & output shafts
 Part List of Drive System

Sr.No Comp.No Name of Part Qty M anual No.

1 1 Motor 1 TTC/04/02 29 9.1 Roller Follow er 1
2 1.1 Bearing 1 TTC/02/05 30 9.2 Bush 2 TTC/MECH/02
3 1.2 Gear Box 1 TTC/02/04 31 9.3 Follow er Lever 2
4 2 Idler sprocket 1 TTC/02/04 32 9.4 Tension spring 2 TTC/02/07
5 3 Chain Drive 1 TTC/02/06 33 10 Groove Cam ( Rack rod Fill ) 1 TTC/02/02
6 3.1 Sprocket 2 TTC/02/06 34 10.1 Roller Follow er 1
7 3.2 Chain 1 TTC/02/06 35 10.2 Bush 1
8 3.3 Bush 2 36 10.3 Follow er Lever 1
9 4 Profile Cam (Tube Ejector) 1 TTC/02/02 37 11 Cam ( Tube Lifter) 1 TTC/02/02
10 4.1 Roller Follow er 1 TTC/02/02 38 11.1 Roller Follow er 1
11 4.2 Bush 1 39 11.2 Bush 1 TTC/MECH/02
12 4.3 Follow er Lever 1 40 11.3 Follow er Lever 1
1 41 11.4 Lifter rod 1
13 4.4 Tension Spring TTC/02/07
2 42 12 Cam (Tube alignment) 1 TTC/02/02
14 4.5 Ejector rod
1 43 12.1 Roller Follow er 1
15 5 Groove Cam (Tube press) TTC/02/02
2 44 12.2 Bush 1 TTC/MECH/02
16 5.1 Roller Follow er
45 12.3 Lifter rod 1
17 5.2 Bush 2
46 13 Cam (Tube lift Filling) 1 TTC/02/02
18 5.3 Follow er Lever 1
47 13.1 Roller Follow er 1
19 5.4 Pressing cone rod 2
48 13.2 Bush 1 TTC/MECH/02
20 5.5 Pressing Cone 2
49 13.3 Tension Spring 1 TTC/02/07
21 6 Cam (Tilter) 1 TTC/02/02
50 14,15,16 Spur gear 3
22 6.1 Roller Follow er 3
51 17 Cylindrical cam 1 TTC/02/02
23 6.2 Bush 1
52 17.1 Index bearing 8
24 6.3 Follow er Lever 1
53 17.2 Railing chain 1
25 6.4 Tension Spring 1 TTC/02/07
54 18 Belt Drive 1 TTC/02/03
26 6.5 Tilter rod 1
55 18.1 V Belt 1 TTC/02/03
27 7,8 Cam (Photocutt off) 2 TTC/02/02
56 18.2 Groove Pulley 2 TTC/02/03
28 9 Cam (Piston Rotary valve) 1
 HSQ LUBRICATION SYSTEM
17 18 19 20 9 10 11 12

ts
EEEE EE EE
JB -3 JB -2 No. Name Qty.

in
1 - Grease [AP-3] 6Kg.
21 22 23 24 13 14 15 16

o
25 26 27 28 33 34 35 36
2 - Grease Pump 1No.
3 - Direction Control Valve 1No.

p
EE EE EEEE
JB -4 JB -5 Line Blind 4 - Junction Box 8Nos.

g
5 - Piping & Joints 4Nos.
29 30 31 32 37 38 39 40
6 - Terminals *64Nos.

in
57 58 59 60 [*Refer Details List ]

s
EEEE
6 - Terminals
JB -8 Line Blind

a
5 - Piping & Joints

e
61 62 63 64

r
4

G
49 50 51 52 3 8 2 - Grease Pump

EE EE
JB -1
EE EE 2 7
1 - Grease
1 6
JB -7
5

53 54 55 56
4 - Junction Box
41 42 43 44
EE EE
JB -6

45 46 47 48

3 - DCV
 HSQ LUBRICATION SYSTEM
LIST OF TERMINALS
NO. LINE DETAILS SECTION NO. LINE DETAILS SECTION
1 - Cam Lever Pin Heater Section 33- Turret Shaft Bush Turret Section

2 - Cam Lever Pin Heater Section 34- Blind

3 - Balancing Lever Pin Heater Section 35- Blind

4 - Balancing Lever Pin Heater Section 36- Clutch Shaft Bush [Cent.] Drive Section
5 - Eccentric Cam Bush [LS] Plough Section 37- Dowel Cam Shaft Bush [RS] Plough Section
6 - Plough Bracket Bush [LS] Plough Section 38- Plough Sliding Bracket Plough Section
7 - Main Drive Shaft Bush [LS] Drive Section 39- Blind

8 - Lifting Cam Shaft Bush [LS] Plough Section 40- Blind

9 - Lifting Cam Shaft Bush [RS] Plough Section 41- Blind

10- Eccentric Cam Shaft Bush [Cent.] Plough Section 42- Wrapper Feed Rubber Roller Shaft Bush [RS] Wrapper Section
11- Plough Bracket Shaft Bush [RS] Plough Section 43- Pusher Bracket Shaft Bush Pusher Section
12- Main Drive Shaft Bush [RS] Drive Section 44- Bevel Gear Conveyor Section
13- Main Drive Shaft Bush [Cent.] Drive Section 45- Dowel Cam Shaft [LS] Pusher Section
14- Clutch Shaft Drive Section 46- Dowel Cam Shaft [RS] Pusher Section
15- Idler Gear Drive Section 47- Lifting Bracket Shaft Bush [LS] Pusher Section
16- Plough Lifting Bracket Bush [RS] Plough Section 48- Lifting Bracket Shaft Bush [RS] Pusher Section
17- Parallel Indexer [RS] Turret Section 49- Wrap. Feed Front Rubber Roller Shaft Bush Top [LS] Wrapper Section
18- Wrapper Feed Belt Drive Shaft [RS] Wrapper Section 50- Wrap. Feed Front Rubber Roller Shaft Bush Bot. [LS] Wrapper Section
19- Idler Sprocket Wrapper Section 51- Wrapper Cutting Knife Bearing [LS] Wrapper Section
20- Blind 52- Wrap. Feed End Rubber Roller Shaft Bush Top [LS] Wrapper Section
21- Idler Sprocket Pusher Section 53- Wrap. Feed Metallic Roller Shaft Bush Bot. [LS] Wrapper Section
22- Idler Sprocket Turret Section 54- Photo Cell Cam Shaft Bush [LS] Wrapper Section
23- Eccentric Cam Shaft Bush [RS] Plough Section 55- EP Cycle Gear Shaft Bush [LS] Wrapper Section
24- Idler Sprocket [RS] Wrapper Section 56- Helical Gear Shaft Bush [LS] Wrapper Section
25- Idler Sprocket [Center] Wrapper Section 57- Wrap. Feed End Rubber Roller Shaft Bush Top [RS] Wrapper Section
26- Blind 58- Wrapper Cutting Knife Bearing [RS] Wrapper Section
27- Blind 59- Wrap. Feed Front Rubber Roller Shaft Bush Bot. [RS] Wrapper Section
28- Idler Gear of Parallel Indexer Turret Section 60- Wrapper Feed Front Rubber Roller Shaft Bush [RS] Wrapper Section
29- Tab. Infeed Belt Conv. Big Pulley Conveyor Section 61- Wrap. Feed Metallic Roller Shaft Bush Bot. [RS] Wrapper Section
30- Tab. Infeed Belt Conv. Tens.Pulley Conveyor Section 62- Photo Cell Cam Shaft Bush [RS] Wrapper Section
31- Idler Sprocket of Pusher Drive Chain Pusher Section 63- EP Cycle Gear Shaft Bush [RS] Wrapper Section
32- Idler Sprocket of Wrap. Drive Chain Pusher Section 64- Helical Gear Shaft Bush [RS] Wrapper Section
 Part Problem Matrix of Drive System

System : DRIVE Equipment : GAN Circle : Sangam Date: 25.01.2001

Abnormal Wear Abnorma Tube Tube Machine
S.No Items Broken Stuck sound l heat up Shift Damag Leak Stoppage
e
1 V Belt
2 Gear Box
3 Chain & Sprocket
4 Cam
5 Follower
6 Lever
7 Spur Gear
8 Cylindrical cam
9 Follower Spring
10 Bearing
11 Bush

Happened before May happen in Future Will never happen

 Inspection Manual by Each Part - capping Machine
Assembly Reference Confirmed Date of
Section Section Prepared by Revision
Name No. by Preparation
Inspection Manual by Each Part
Infeed
Infeed worm Infeed worm S Palamwar Sunder Mahajan 01.01.01
worm

Structural diagram ( Disassembly diagram ) Basic functions of this part :

One of the sections that is used to drive the worm which ultimately transfer the pucks into the star wheel.
Past Problems
Specific Phenomena and occurences Frequency D/T (mins)
Date/shift

Is preparation of one-point
Procedure of lesson materials
Inspection Machine KNOW - WHY
No. actual Criteria necessary
item Status ( Why is inspection, restoration or improvement necessary ? )
inspection
Steps to be taken
1 Lubrication Visual To keep the chain Grease the chain with Grease running out on the chain rollers >>> jamming of rollers >>> abnormal
of chain inspection lubricated grease gun wear of chain and sprockets >>>chattering >>> slippage / breakage of chain
N Running and/or sprockets >>> inability to transmit motion >>> machine stoppage.

2 Chattering Visual No chattering occurs Check alignment of Chattering of sprockets >>> abnormal wear of chain and sprockets >>>
and wear of inspection when it is running drive, driven and idler slippage / breakage of chain and/or sprockets >>> inability to transmit motion
the drive sprockets, if not ok do >>> machine stoppage.
Y Running
and driven disassembly
sprockets inspection

3 Chattering Visual No chattering occurs Check alignment of Chattering of gears >>> abnormal wear of gears >>> slippage / breakage of
and wear of inspection when it is running drive & driven gears, if gears >>> inability to transmit motion >>> machine stoppage.
the drive not ok do Y Stopped
and driven disassembly
gears inspection
4 Improper Visual Smooth entry , No Check the position of Improper entry of pucks/bottle >>> jumping of pucks at entry >>> damage of
entry of inspection vibrations worm pucks/bottles >>> machine stoppage.
puck into Check the position of
Y Running
worm entry guard in front of
worm
 " ,- +"

+ +
" +" " +" " +"

" 2 6" ' ' 2 6"

/
- -
/ /
$
- ' "
/ / -
45
&
& ) 8 1
,/
- 4
/ 7 +
7 + "
5 6 4
-
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2 6 /
& + " + 9
-
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'
45
" + +
)8 1
'+ +
 Overall Inspection, Jishu Hozen Step - 4
Process Point Analysis : Shampoo Filling Machine

Wteight setting by adjusting the

height of cam track

System that maintains the continuity of the processing point

Plough Pusher feeds the tablet in
between the End Heater Blocks

Centralized Lubrication System

End Heater Lubrication of cams & cam followers
Housing Blocks pins/bushes, chain and sprockets
Movements of heater blocks carriers and
brackets
Drive and Transmission system - cams
shaft , sprockets, chain
Ref. Flow diagram & inspection
sheets of individual components
Oilers / Greasers Ref. Individual
items inspection sheets
Main Drive shaft and motor. Ref.
Drive section flow diagram and
inspection sheets of ind. Comp.

Mistcool Lubrication System Ref.

Tablet Lubrication on wrapped tablet outer surface
Movement of plough bits on sliding plate
Drive to plough pusher levers by connecting
rods, cams, shafts and gears
Flow diagram & inspection
sheets
Plough pusher lever. Ref. System
Diagram and inspection sheets of
individual components
Plough section drive. Ref.
System Diagram and inspection
sheets of individual components

System that positions the processing point

Heater housing carriers , Fasteners , cam levers , balancing levers , cams & cam
End Heater Blocks
followers , pins/bushes

Tablet SS supporting plates between the heater block.

SS guide plates of the folding section
Heater housing carriers

System that forms the processing point

Processing condition system

End Heater Timing - End heater housing blocks "Open" while tablet entry = 4 mm. "Closed"
Housings Blocks while tablet stationary.
Stroke - Depending on machine speed. 125 gms. and 250 gms. = 160 TPM
Displacement of housing blocks - 4 mm
Alignment - Right angle - 90 o to SS supporting plates plates
Surface of heating plate - Smooth
Gap between both heating surfaces (in MM) -100 gms. = 73, 125 gms. = 78, 150
gms.= 93.6, 250 gms = 106 , 300 gms. = 127.2, 400 gms Vim = 104, 200 gm Vim
Temperature of heating surface - 150 O C

Teflon tape condition - Smooth and even 50 mm width

Processing Aids
LLPO = 0.83 Sp. Gravity

Length (in MM) -100 gms. = 73, 125 gms. = 78, 150 gms.= 93.6, 250 gms = 106 ,
Tablet
300 gms. = 127.2, 400 gms Vim = 104, 200 gm Vim = 92.
Softness - PV not more than 26
Both end sealing surfaces- flat, right angle
Shape - Rectangular

Width in MM -100 gms. = 104, 125 gms. = 110, 150 gms.=126, 250 gms = 147,
Wrapper
300 gms. = 168, 400 gms vim = 154, 200 gm vim = 123.
Polylayer = 12 GSM
Folds as per standard
Identifying Processing Points

P1 Product filling in hopper

P2
Product filling in bottle

P3
Bottle entry
 Equipment Quality Process Table

Equipment Quality Process Table

Process : Photocell Tube Centering

Equipment : Gan Machine

Quality Assurance Item Match of Photocell

Characteristics Standards Daily Quality

Unit Processing Condition Motion System Tool System Processing Aids

Section 1. Step Motor 1.Scanner Head 1.Magnetism
1. Lifter Rod Mechanism
2. Lifter rod
Control 1.1 Photocell Rod Setting 1.1 Play 1.1 Sensitivity 1.1 Magnetic property
1.2 Lifter Assembly Lubrication
1.2 Mounting Bolts 1.2 Scanner Bracket 1 1.2 Cone Spring
Processing Items
1.3 Electrical Connection 1.3 Scanner Bracket 2 1.3 Cone knunling
Condition 2.1 No Bearing Jam 1.4 Cone grub Screw
Control 2.2 No play in lift rod
Items Standards 1.1.1 60 gm 56 mm 1.1.1 Play not > 0.5 mm 1.1.1 Dot intensity of rays 1.1.1 Should have magnetism
1.1.2 70 gm 61 mm 1.2.1 Match mark 1.2.1 No deviation from mark 1.2.1 No abnormal elongation
1.1.3 150 gm 65 mm 1.3.1 No wire loose 1.3.1 No deviation from mark 1.3.1 No bluntness
2.1.1 Free rotation 1.4.1 No bluntness,Looseness
1.2.1 Proper Oiling of Lifter
2.2.1 Play not > 0.5 mm
bushes and Cam track

Person Incharge Technician Technician Technician Technician

Conformation Visual Inspection / Visual Inspection /

Visual Inspection Visual Inspection
Method Vernier Calliper Magnifying Glass
Conformation
Daily Once per Month Once per Month Once per Month
Frequency
Measure in
Inform Shift Officer Inform Shift Officer Inform Shift Officer Inform Shift Officer
Emergency
 !

Confirmati Reason for

Condition Reason for Basis for confirmatio Measures in
No. Standards on determining
control item control standard setting n method emergency
Frequency frequency
1 Motion system
Restricts entry of Correlation between
Positive cutoff rod Upward position Past Do the proper
product into the setting and product Ref OPL no. Weekly
setting during filling performance setting
bottle filling

Affects the Correlation between By manual Remove the

Jamming of rotary Past
discharge product Free movement rotary valve movement movement of Weekly valve,clean it
valve performance
volume and wt of the product valve and replace

Correlation between Reporting to

Wear of Cams and Affects movement Past
0.2mm wear volume and piston Dial Gauge Quarterly Maintenance/
Followers Faces of piston performance
movement Shift Officer

Correlation between By manual

Pneumatic cylinder Affects opening of Past Reporting to
Free movement cylinder movement and movement of Quarterly
movement rotary valve performance Shift Officer
rotary valve movement cylinder shaft

2 Tools System
3 Processing Aids
 Condition Control Know - Why Analysis
Reason of Measures
Conditon Control Reason for Basis for Standard Confirmatio Confirmation
No. Standard setting in
Items Control setting n method Frequency
Freq. Emergency
Play in Motor shaft Motor shaft No play Correlation with Visual Bimonthly Past Inform Shift
causes oblonge rotation of tube Inspection Performance Officer
Motion System

Electrical rotation
Malfunction in No Loose Correlation with Visual Weekly Past Retight the
Connection motor rotation motor rotation Inspection Performance wires
Bearing Jam Improper Free rotation Correlation with Visual Weekly Past Inform Shift
movement of Tube movement Inspection Performance Officer
Lifter Rod Play Tube
Improper No Play Correlation with Visual Bimonthly Past Inform Shift
movement of Tube movement Inspection Performance Officer
Tube
Improper Dot mark Correlation with Visual Monthly Past Set intensity
Sensitivity
eyemarkSensing Offcentering of tube Inspection Performance to Dot mark
Tool System

Improper Tube No Looseness Correlation with Visual Quarterly Past Retight the
Scanner Bracket 1
Sensing Offcentering of tube Inspection Performance allen bolts
Improper Tube No Looseness Correlation with Visual Quarterly Past Retight the
Scanner Bracket 2
Sensing Offcentering of tube Inspection Performance allen bolts
Improper Tube Should be Correlation with Cleaning Monthly Past Remove any
Magnetic property
rotation clean from rotation of tube Performance foreign
Processing Aids

Improper Tube dustabnormal

No Correlation with Visual Quarterly Past matter
Replace with
Cone Spring
rotation elongation rotation of tube Inspection Performance new spring
Improper Tube No bluntness Correlation with Visual Quarterly Past Replace with
Cone knunling
rotation rotation of tube Inspection Performance new cone
Improper cone No looseness Correlation between Visual Monthly Past Retight the
Cone grub Screw
movement of screw cone and motor Inspection Performance screw
shaft
 Shampoo Filling Machine - Infeed Worm Section
Sr. No. Comp. No. Name of Main Parts Qty. OPL No. Manual No.
1 1 Drive Bevel Gear 1 No.
2 2 Driven Bevel Gear 1 No.
3 3 Shaft 1 No.
4 4 Drive Sprocket 1 No.
5 5 Idler Sprocket 1 No.
6 6 Chain 1 No.
7 7 Driven Sprocket 1 No.
8 8 Shaft 1 No.
9 9 Drive Spur Gear 1 No.
10 10 Idler Spur Gear 1 No.
11 11 Driven Spur Gear 1 No.
12 12 Shaft 1 No.
13 13 Worm Shaft 1 No.
Sr. No. Comp. No. Name of Sub Parts Qty. (Nos.) OPL No. Manual No.
1 1 Drive Bevel Gear 1
2 1.1 Key 1
3 1.2 Grub Screw 1
4 2 Driven Bevel Gear 1
5 2.1 Key 1
6 2.2 Grub Screw 1
7 3 Shaft 1
8 3.1 Bearing 2
9 3.2 Hex. Bolt 3
10 3.3 Snap Ring 2
11 4 Drive Sprocket 1
12 4.1 Key 1
13 4.2 Grub Screw 1
14 5 Idler Sprocket 1
15 5.1 Hex. Pin 1
16 5.2 Hex. Bolt 1
17 5.3 Hex. Nut 1
18 5.4 Washer 1
19 6 Chain 1
20 6.1 Links
21 6.2 Lock 1
TRAINING MANUALS
 TTC

is set up to facilitate

Technical
training
needs
 LAYOUT OF TECHNICAL TRAINING
CENTRE
8
3
4
9 7 6 5
10
Socket

Main Electrical Switch Board Fan Starter

distribution
11 supply board

2 2 2 2
15

2 2 2 2
12
16 15 14 15

13
15

1
17

You are here

1. Electronic trainer 2.Chairs for Training 3. White Board

4. Television &VCP 5. Spare Parts for Pneumatic Trainer 6. Pneumatic Trainer
7. Electrical trainer 8. Pipe Fitting Trainer 9. Do Nothing Machine
10.Centrifugal pump Trainer 11.Safety Equipment Model 12.Various cut-sections
13.Mechanical Drives 14.Discussion Table 15.Discussion Chair
16.HSQ Machine Model 17.Drawers for inspection items
STAGE 2

TRAINING
 General Inspection Course for Operator

Tutor:- Engineering Officer 4 Hrs

impart knowledge for upgrading skills of an operator to carry out Autonomous maintemance Activities
Undressing the structure , function and principle of belt drive and its ideal status.
Obtaining skill that enable inspection of the mechanism of various types of Drives
Inspection main function parts ,identifying latent defects and resting it to its original state
5) working model
6) Cutaway
L : Lecture
7) Flow chart
8) System diagram
Teaching Materials Location Reference Minutes Form

TTC TTC/O2/03 30 L
Manual on Belt and pulley
OPL'S
General inspection sheets
TTC
TTC
TTC
TTC/O2/03

30 L , G.D. D
GD: Group
Discussion
Working model TTC
System diagram TTC
Manual on Belt and pulley TTC TTC/O2/03
OPL'S TTC
General inspection sheets TTC 30 L , G.D. D

Working model TIC

System diagram TIC
Manual on Belt and pulley TTC TTC/O2/03
OPL'S
General inspection sheets
Working model
TTC
TTC
TIC
40 L , G.D. D
D: Demonstration
System diagram TTC
Manual on Belt and pulley TTC TTC/O2/03
OPL'S TTC
L , G.D. D
General inspection sheets TTC 35

Working model TTC

System diagram TTC

E: Evaluation
Manual on Belt and pulley TTC TTC/O2/03
OPL'S TTC
General inspection sheets TTC 30 L , G.D. D

Working model TTC

System diagram TTC
30 G,D&E
15 E
 General Inspection Course for Operator
GENERAL INSPECTION COURSE FOR OPERATORS

Date Prepared : 20th Dec. 2000

Cours e
Prepared by : Sunder Mahajan/Shantanu Shukla

Ite m Electricals Tutor : Electrical Off icer Duration 7 Hrs.

Aim To im part know le dge for upgrading sk ills of an ope rator to carry out Autonom ous Maintenance Activities

Purposes 1) Understanding the structure, f unctions and principles of various types electrical systems and its ideal status

2) Obtaining skills that enable inspection of the primary mechanisms of various types of electrical systems

3) Inspecting main f unctional parts, identif ying latent def ects, and restoring it to its original state
Teaching 1) Text / Manuals 5) Working model
Materials
2) OPL's 6) Cutaw ay model

3) General inspection sheets 7) Flow chart

4) Video tapes 8) System diagram

No. Training Subje cts Te aching Mate rials location Sr.no. Minutes Form

1 Electricity Manual on Electrical systems TTC 60 L

Induction Motors Manual on Electrical systems TTC

a) Types, structure & functions OPL's TTC

2 60 L,P & D
b) RPM / Ratings General inspection sheets TTC
c) Do's and Don'ts Cutaw ay model TTC
d) General inspection points System diagram TTC

Relays Manual on Electrical systems TTC

a) Types, structure & functions OPL's TTC

3 45 L,P & D
b) Ratings / Setting General inspection sheets TTC
c) Do's and Don'ts Working model TTC
d) General inspection points System diagram TTC

Contactors Manual on Electrical systems TTC

a) Types, structure & functions OPL's TTC

4 45 L,P & D
b) Ratings / Setting General inspection sheets TTC
c) Do's and Don'ts Working model TTC
d) General inspection points System diagram TTC

L : Lecture D : Self-teaching & Dis cus sion P : Practice W : Written

 Training Calendar for Operator
TOPIC SUB TOPIC DATE DURATION TIME CIRCLE

BOLTS AND SCREWS , STUDS ,NUTS, WASHERS

08/01/01 240 MINUTES 11.30 TO 15 .30 SANGAM
FASTENER
KEYS AND KEYWAYS , TAPER PINS ,GRUB 10/01/01 240 MINUTES 11.30 TO 15 .30 SANGAM
SCREWS , CIRCLIPS
SPROCKETS AND CHAINS . 11/01/01 240 MINUTES 11.30 TO 15 .30 SANGAM

CAM & CAM FOLLOWERS 15/01/01 240 MINUTES 11.30 TO 15 .30 SANGAM

DRIVE SYSTEMS BEARING 19/01/01 240 MINUTES 11.30 TO 15 .30 SANGAM

GEARS 23/01/01 240 MINUTES 11.30 TO 15 .30 SANGAM

PULLEY & BELTS 29/01/01 240 MINUTES 11.30 TO 15 .30 SANGAM

AIR PRESSURE SUPPLY SYSTEM , FILTERS, PRESSURE

08/02/01 240
CONTROL
MINUTESVALVE,
11.30 TO 15.30 SANGAM
PNEUMATIC SYSTEM
OILERS , DIRECTION CONTROL VALVE , 15/02/01 240 MINUTES 11.30 TO 15.30 SANGAM
FLOW CONTROL VALVE, ACTUATOR.

CONTRACTOR 22/02/01 240 MINUTES 15.30 TO 19.30 SANGAM

TIMER 02/03/01 240 MINUTES 15.30 TO 19.30 SANGAM

ELECTRICAL
SYSTEM RELAYS 03/03/01 240 MINUTES 15.30 TO 19.30 SANGAM

PHOTO SWITCH 05/03/01 240 MINUTES 15.30 TO 19.30 SANGAM

INDUCTION MOTOR 06/03/01 240 MINUTES 11.30 TO 15.30 SANGAM

LUBRICATION MANUAL LUBRICATION 12/03/01 240 MINUTES 15.30 TO 19.30 SANGAM
SYSTEM
EARTHING 15.03.2001240 MINUTES 15.30 TO 19.30 SANGAM
SAFETY GUARDS
SAFETY INTER LOCK
 Conducting Basic Training

Toy M/c

L GD D

Sr.No Name Qualification Designation Grade

1 Ade Electrician Trainee A

2 G Dhande Fitter Trainee A
3 P Patil Fitter Trainee A
4 Karpate Electronics Trainee A
5 Malekar SSC W2 B
6 Bansod B Com Trainee B
7 Nagalkar SSC W1 B

Performance Rating Scale Recommendation for next Training.

Garde A : More than 80% marks
Grade B : More than 60% marks
Grade A: 6 Months
Grade B: 3 Months
E
(Refresher Course)
(Bridging Gap) D
Grade C : C Less than 60% marks Grade C: 1 Month ( Back To Basics)
Actual M/c
 STAGE 3

GENERAL INSPECTION
Implementation
Overall Inspection Schedule
TOPIC SUBTOPIC DATE TIME ALLOTED SESSION CIRCLE

BOLTS,NUTS,WASHERS 7.00 TO 11.00

FASTNERS 12.02.01 240 MIN SANGAM
,& KEY AM

BEARING & BUSHES

DRIVE GEARS 7.00 AM TO
17.02.01 420 MIN SANGAM
SYSTEM CAM AND FOLLOWERS 3.30 PM
SPROCKETS
DIRECTION CONTROL VALVE
PNEUMATIC FILTER,REGULATOR ,OILER 7.00 TO 11.00
24.02.01 240 MIN SANGAM
DRIVES PIPES & JOINTS FITTING AM
FLOW CONTROL VALVE
PROXIMITY SWITCH
ELECTRICAL ON/ OFF SWITCH 7.00 AM TO
7.03.01 420 MIN SANGAM
SYSTEM LEVEL CONTROLLER CONTACTOR 3.30 PM
MOTOR
MANUAL LUBRICATION
LUBRICATION 7.00 TO 11.00
15.03.01 240 MIN SANGAM
SYSTEM AM

EARTHING
GUARDS 7.00 TO 11.00
SAFETY 17.03.01 240 MIN SANGAM
SAFETY INTER LOCK AM
 "
Process :Bars Equipment : HSQ wrapping Machine Section : End Heater Prep.by :R.B.Waghole Date : 19.08.00 Revision :0 Machine : HSQ R3 Date of Inspection: 17.08

.
ty

O ply
t
c.
Abnormal Items

ui
op

h
Comp.

s
ff

ed

pe

g
ng

p
rc
he

E
ff
rO

Dr
Sr. No.

Hi
e

Su
ty
e
ng

nt

nt

st
m
O

Ci

ff
os

uc

m
i

tc
ok
No.

ak

r
Inspection

Lo
m
Be

De

of

s.

s.
ki

ea

ra
y

Lo

ra
Di

r
St
Br

t
Fl

Ja

e
Le

we
or
ut
ec

Sc

og
Pr

Pr
Items/Parts

Sh

Po
O
Ch

Pr
1 1 Drive Sprocket 1 No.
2 1.1 Taper Pin 1 No.
3 1.2 Grub Screw 1 No.
4 2 Idler Sprocket 1 No. X
5 2.1 Bush Pin 1 No.
6 2.2 Washer 1 No.
7 2.3 Nut 1 No.
8 2.4 P.B.Nipple 1 No.
9 3 Chain 1 No.
10 3.1 Links Nos.
11 3.2 Lock 1 No.
12 4 Driven Sprocket 1 No. X
13 4.1 Taper Pin 1 No.
14 4.2 Grub Screw 1 No.
15 5 Cam Shaft 1 No.
16 5.1 Lock Bush 1 No.
17 5.2 Grub Screw 1 No.
18 6/7 Plate Cams 2 Nos.
19 6/7.1 Taper Pins 2 Nos. 1 X
20 6/7.2 Grub Screws 2 Nos.
21 8 Fulcrum Shaft 1 No.
22 8.1 HH Bolts 2 Nos.
23 8.2 Washers 2 Nos.
24 8.3 Nuts 2 Nos.
25 8.4 Brass Nipples 4 Nos. 1 X 1 X 1 X
26 8.5 Grub Screws 4 Nos. X
27 9/10 Cam Levers 2 Nos.
28 9/10.1 P.B.Bushes 8 Nos. 4 X
29 9/10.2 Pins 2 Nos.
30 9/10.3 Collar Pins 2 Nos. X 1 X
Fuguai Identification for each Category

11 Fuguai
WE SEARCHED THEM Identified

3 3

Bend Jam Loose Heat up

Fuguai Stratification
 7 4
:( %;=
& *;
#=
-
;=
6+ *;
#=

%
"

: '
:(
& &
. *%;
<:=
5 6

Equipment Parts Inspected Defective parts Rate

Main body 2129 99 4.60%
Auxillary 232 7 3.00%
Others 824 90 10.90%
 JH IMPROVEMENTS
List of Fuagais Identified By whom Date Cause Action taken Pillar Linkage Benefits
KK PM JH

Mounting bolts were made up

*
Lifting assembly mounting All MS bolts replaced with No breakdown
Sanjay 20/01/01 of MS which were started
bolt broken SS bolts due to lifter
rusting because of the contact
of highly corrosive shampoo

Checking of tightness of the

No disturbances

*
Loosening of sprocket on the sprocket on the shaft include
Wearing of Shaft Key way Sunder 21/01/01 in the worm
shaft in Time based maintenance
setting
checksheet

Checking of tightness of the

No disturbances

*
Loosening of sprocket on the sprocket on the shaft include
Damaged Key Jayesh 21/01/01 in the worm
shaft in Time based maintenance
setting
checksheet

No bottle

Brocken lifting springs
* *
Visual checking included in rejection due to
Sharan 20/01/01 No visual inspection
CLI std and replacement of improper
springs included in TBM centering

Support provided to the No

*
Crack in the product filling Friction between pipe and
Dave 24/01/01 product filling pipe to avoid contamination in
pipe moving hopper
friction product

*
Wearing inside the valve Misalignment of shaft inside Checking of allignment Elimination of
Sachin 24/01/01
housing block the housing started thro' CLI checksheet dead ends

No product
*
Teflon bush locking bolt Replaced all bolts with SS
Dave 24/01/01 Corrosion (MOC - MS) leakage thro'
broken bolts
bush.
 Improvements of Fuguai

BEFORE AFTER

Main Cause
 Improvements of Fuguai

BEFORE AFTER

Allen Bolt was loose.

Bolt provided with Spring Washer and 2 Allen bolts used
VISUAL CONTROL - PokaYoke

Transfer
Pump ON

Air
Compressor
Trip

Motor
Fan ON

Machine
Door Open
VISUAL CONTROL - PokaYoke

Filling Machine
Door open and pump trip

Motor Fan

Capping Machine
Door open and
conveyors ON

Air Compressor
trip
 Overall Inspection , Jishu Hozen Step - 4
Know-why Sheet
Component Date of
Process Section Assembly Name Part Name Confirmed by Prepared by Revision
No. Preparation
Shampoo Infeed
Drive B1FM003 Shaft Sachin P. Shantanu/Sunder 01.03.2001 -
Filling Worm
Structural diagram ( Disassembly diagram )
Basic function of this part : To transmit the motion Bevel gear to chain sprocket

Name : Shaft

Specifications : OPL No. B1FMS001

Function : Bevel gear get motion from another drive Bevel gear and transfer the
motion to the chain sprocket which ultimately drives infeed worm thro another gear
assembly.

Inspection Inspection Action if found OPL

No. Criterion / Standard Who KNOW - WHY
Item Method Abnormal No.
1 1.1 Keyway damaged1.1.1 Visual 1.1.1.1 No looseness of 1.4 Stop the Machine Operator Keyway of the Shaft got damaged

1.1.1.2 No chattering 1.4.1 Remove the idler Loosening of Key / damage of key

1.1.2 By vernier calliper

1.1.2.1 As per specification 1.4.2 remove the chain Slippage of Drive sprocket

1.4.3 Loose the grub screw Trasfer of motion to the worm gets affected

1.4.4 Remove the sprocket Jumping of Bottles/pucks at Worm entry

1.4.5 Open the gear housing Machine will stop

1.4.6 Loose the grub screw of

bevel gear

1.4.7 Remove the shaft

1.4.8 Replace the shaft

 Overall Inspection, Jishu Hozen Step - 4
Tentative Routine Inspection Standards Month : January ' 01

Process : Sham poo Equipm ent : Bottling line 1 Section : Bottle centering Machine : Filling Machine Revision : -

Tools and State of Tim e Frequency Person Schedule

No. PART Item to be Inspected Standards
Methods Equipm ent (Mins.) (Once per) Incharge Wk. 1 Wk. 2 Wk. 3 Wk. 4 Wk. 5

Lifting spring No breakage Visual inspection Operating 5 Weekly Operator

Lifting
1 Wearing of lifting shaft <0.2mm Dial gauge Stopped 20 Quaterly Operator
Assem bly

Greasing on shaft Proper lubrication Visual inspection Operating 5 Daily Operator

Freee movement on
Cam follow er Visual inspection Operating 5 Quaterly Operator
track
2 Cam track
Wear and tear of shaft <0.5mm Dial gauge Stopped 20 Quaterly Operator

Wear and tear of star w heel No w ear Visual inspection Operating 5 Quaterly Operator

3 Starw heel Breakage of star w heel No breakage Visual inspection Operating 5 Quaterly Operator

Play in the star w heel No play Visual inspection Operating 6 Quaterly Operator

Breakage of neck guide No breakage Visual inspection Operating 5 Quaterly Operator

4 Neck Guide Bending of neck guide No bent Visual inspection Operating 5 Quaterly Operator

Play in the neck guide No play Visual inspection Operating 5 Quaterly Operator

Wear and tear of Bottle

Bottle No w ear and tear Visual inspection Operating 3 Quaterly Operator
centering guide.
5 centering
guide Play No play Visual inspection Operating 5 Quaterly Operator

Wear and tear of puck guide No w ear and tear Visual inspection Operating 3 Quaterly Operator
6 Puck guide
Jamming of puck guide No jamm. Visual inspection Operating 3 Quaterly Operator

Jamming of Lifter plate No jamm. Visual inspection Operating 5 Quaterly Operator

7 Lifter Plate
Play No play Visual inspection Operating 6 Quaterly Operator

Operators Rem arks : Officers Rem arks : Managers Rem arks :

 Overall Inspection, Jishu Hozen Step - 4
Table of Routine Inspection Standards for Equipment Quality Month : February 01
Process :
Equipm ent : Bottling line 1 Section : Product filling section Machine : Filling Machine Revision : -
Sham poo

Spot to be Tools and State of Tim e Frequency Person Schedule

No. System Standards
Inspected Methods Equipm ent (Mins.) (Once per) Incharge Wk. 1 Wk. 2 Wk. 3 Wk. 4 Wk. 5
1.1.1 80ml 145 mm Visual inspection
1.1.2 100ml 132 mm Visual inspection
1.1Height of cam
Processing 1.1.3 160ml 113 mm Visual inspection Operating 1 shift Operator
track
1 Condition 1.1.4 200ml 087 mm Visual inspection
System 1.1.5 300 ml 060 mm Visual inspection
1.2 Lubrication of 1.2.1 Proper oiling on cam
Visual inspection Operating 2 Shift Operator
cam track track
1.1 looseness of
1.1.1 Should match the mark Visual inspection Operating 2 Daily
locking screw
1.2.1 No breakage
1.2 Damage of spring Visual inspection Operating 4 Daily Operator
(Spec no. B1FM0021G )
Motion
2 1.3 'O' ring of valve
System 1.3.1 Spec. no. B1FM0021B Vernier calliper stopped 4 Quaterly
block
2.1 Piston teflon ring 2.1.1 Spec. no. B1FM0020H Vernier calliper stopped 6 Quaterly
2.2 Piston 'O' ring 2.2.1 Spec. no. B1FM0020H Vernier calliper stopped 6 Quaterly Operator
2.3 Piston pin 2.3.1 No bent/damage Visual inspection stopped 5 Weekly
1.1 Profile - w earing
Dial gauge stopped 10 Half yearly
of cam 1.1.1 <0.1mm
1.2 Positiion -
Tools Visual inspection stopped 8 Half yearly
3 Slippage of cam 1.2.1 Ref. OPL no. 574 Operator
system
1.3 Positive cutoff
Ref OPL no. Operating 15 Daily
rod setting 1.3.1 Ref. OPL no. 204
1.4 Nozzle spring 1.4.1 No damage Visual inspection stopped 15 Weekly
1.1 Position of
2 Daily
sensor 1.1.1 As per visual guide Visual inspection Operating
Processing Operator
4 1.2 Pneumatic 10
aids 1.2.1 Strock length - 40mm Vernier calliper stopped Quaterly
cylinder operation
0.3sec Multimeter stopped 10

Operators Rem arks : Officers Rem arks : Managers Rem arks :

 ACTION / FEEDBACK TO EQUIPMENT DESIGN
Prepared by : K.Gnanaselvam
Date : 15.03.2000

Equipment ; Talc Filling Machine Production Engineering Section : Production At time of :

Destination Section : Mahine Manufaturer ( Autopack) Specification Concept
Accepting Department : Machine Manufaturer Basic Design
Detailed Design

No. Date Source Priority Problem / Action Date Action Cause Result Feed to Details Person
A B Request C D E F resp.
This Machine
To change the bevel gear material from
03.01.20 Incorporate as frequent w earing out of auger drive Modify / Subsequent Improve
1 User Dept. nylon to hardened steel. Drive & Driven 20.02.2000 Design Error Zero Failure K.Gnanaselvam
00 far as possible bevel gear Material and similar reliability
gear to be of same hardness
models

Nylon Gear Assembly -

Hardened Gear Assem
Before

Key

A. Information Source B. Priority C. Action D. Cause E. Feedback destination F. Feedbac

1. Fabrication dept. (In house)1. Incorporation 1. Modify structure/ 1. Planning error 1. This machine only 1. Increase proce
mandatory mechanism
2. Fabrication dept. (External) 2. Design error 2. This machine / subsequent 2. Increase capac
2. Incorporation as 2. Modify action / function models
3. Design dept. (In house) far as possible 3. Fabrication error 3. Improve reliabil
3. Modify control circuitry 3. This machine / subsequent and
4. Design dept. (External) 3. Referance requested 4. Specification change similar models 4. Improve mainta
4. Modify surface / heat
5. User dept. treat 5. Improve cost-ef

5. Modify material / shape 6. Improve safety

7. Improve operata
 Time Based Maintenance Sheet
Equipment : Bottle line 1 Frequency : W
Date : Record no : PM/B1/00/
Team :
Shift :

1 2 3 Sr. no. Job description Standard Observation

1 Grease the Filling machine center pillar bearing N. A.
2 Oil the lifter rollers & check the roller operation No spring to ne broken
3 Check the lifter spring & replace damaged spring if any All rollers to rotate freely

4 5 6
4 Check the oil level in the filling m/c gear box Up to the mark
5 Tighten the lifter base plate bolts All bolts to be tight
6 Tighten the roto valve locking bolts N. A.

7, 8 9, 10 11
7 Check the worm for any play of filling m/c N. A.
8 Check the worm for any play of capping m/c N. A.
9 Grease the filling machine centre gears N. A.
10 Grease the Capping m/c centre gear N. A.
11 Check the condiotion of any one piston O ring No leak from the piston area

12 13 14
12 Check the oil level in the capping m/c gear box Up to the mark
13 Check the conveyor slat chains No ink in the print head
14 Check the condition of packing conveyor gear box N. A.

15 16 17
15 Grease the Pago m/c top conveyor chain
16 Check the side belt conveyor
17 Check conditon of any one piston O ring No link to be damaged
 Inspection Skill Check

Skill in Inspection of..

Nut & Bolt
4

Tucking Unit Index Cam

3 Nandu Arbat
No Tube No Fill Spur Gear
2

Gear Box O il Chain

0 - Lack of Knowledge
1 - Know in Theoretical Sense
Electrical Components Chain Sprocket
2 - Can Partially Do it
3 - Can do with Self
Contactor Connection V Belt Confidence
4 - Can Teach Others
Pneumatic Cylinder FRL Unit

Ideal Target Actual Bench Mark

 JH Inspection Time at the end of Step 4

2
11.5
6.3
8.4
9.6
15 min 12.5

12 min
(Mins)

STEP 2 STEP 3 STEP 4

Lubrication
Pneumatic
Fastener

Electrical
Drives
Cleaning

Safety
Cleaning +
Lubrication
STAGE 4

AUDIT
 Date MM Leader
Team
Name :
"Jishu - Hozen" Audit application Form & Sheet

Point Passed Not Passed

Equipment
No :
Acceptable Level = (Items 1 - 5
Step 4-1 : General Inspection (Bolts and Nuts) level points)
Desired date of Audit :

Audit Date : Autonomous MM FM

Audit Autonomous MM FM
More than More than More than
Auditor :
90 points 85 points 80 points

Bad Poor Passable Good Excellent

Item Description Remarks
20 points 40 points 60 points 80 points 100 points

Maintain and Skill (Are step 1 to 3 operated and maintained)

- Are measures to control generating sources

adequately maintained ?
-Are KAIZEN conditions of countermeasures against
source of ourbreaks that are clean?
- Are cleaning and oiling standards adequately
specified and utilized as required?

1point 2 point 3 point 4 piont 5 point

- Do leaders and circle members activety draw up one

point Lessons to upgrade skills?
1. Skill Traning
- Have all members mastered the general inspection
skill?

- Are trained items correctly inspected?

2. General
- Have "Fuguai" Place been found by inspection?
inspection
- Have countermeasures been taken against found
"Fuguai Places?
- Have slight safety defects been found and have
3. Safety
counter-measures for them been taken?

-Check for loose bolts and nuts

-Check for Missing or damaged bolts and nuts.

-Have anti -loosening coutermeasures been taken

where necessery?

-Are plain washers used in slits?

 Date MM Leader
Team
Name :
"Jishu - Hozen" Audit application Form & Sheet

Point Passed Not Passed

Equipment
No :
Acceptable Level = (Items 1 - 5
Step 4-2 : General Inspection (Lubrication) level points)
Desired date of Audit :

Audit Date : Autonomous MM FM

Audit Autonomous MM FM
More than More than More than
Auditor :
90 points 85 points 80 points

Bad Poor Passable Good Excellent

Item Description Remarks
20 points 40 points 60 points 80 points 100 points

(Are step 1 to 3 operated and maintained)

- Are measures to control generating sources

Maintain and adequately maintained ?
Control -Are KAIZEN conditions of countermeasures against
source of ourbreaks that are clean?
- Are cleaning and oiling standards adequately
specified and utilized as required?

1point 2 point 3 point 4 piont 5 point

- Do leaders and circle members actively draw up one

point Lessons to upgrade skills?
1. Skill Training
- Have all members mastered the general inspection
skill?

- Are trained items correctly inspected?

2. General
- Have "Fuguai" place been found by inspection?
inspection
- Have countermeasures been taken against found
"Fuguai Places?
- Have slight safety defects been found and have
3. Safety
counter-measures for them been taken?
- Do oiling places have a label correctly attached and
are ideas incorporated to lubricate all places, without
omissions?

- Is correct oil type used ?

- Is oiling amount appropriate?

- Check for oil deterioration

 Date MM Leader
Team
Name :
"Jishu - Hozen" Audit application Form & Sheet

Point Passed Not Passed

Equipment
No :
Acceptable Level = (Items 1 - 5
Step 4-3 : General Inspection (Drive System) level points)
Desired date of Audit :

Audit Date : Autonomous MM FM

Audit Autonomous MM FM
More than More than More than
Auditor :
90 points 85 points 80 points

Bad Poor Passable Good Excellent

Item Description Remarks
20 points 40 points 60 points 80 points 100 points

(Are step 1 to 3 operated and maintained)

- Are measures to control generating sources

Maintain and adequately maintained ?
Control -Are KAIZEN conditions of countermeasures against
source of ourbreaks that are clean?
- Are cleaning and oiling standards adequately
specified and utilized as required?

1point 2 point 3 point 4 piont 5 point

- Do leaders and circle members actively draw up one

point lessons to upgrade skills?
1. Skill Training
- Have all members mastered the general inspection
skill?

- Are trained items correctly inspected?

2. General
- Have "Fuguai" place been found by inspection?
inspection
- Have countermeasures been taken against found
"Fuguai" places?
- Have slight safety defects been found and have
3. Safety
counter-measures for them been taken?
-Check for wear and deterioration of V-belts and wear
and center misalignment of pulleys.

-Are tentions of V-belts appropriate?

-Is visual control of V-belt covers in place such as belt

rotating direction and belt dimensions?
-Is lube oil fully lubricated between pin and bushing of
chains?
 Date MM Leader
Team
Name :
"Jishu - Hozen" Audit application Form & Sheet

Point Passed Not Passed

Equipment
No :
Step 4-4 : General Inspection (Hydraulic and Acceptable Level = (Items 1 - 5
Pneumatics) Desired date of Audit :
level points)

Audit Date : Autonomous MM FM

Audit Autonomous MM FM
More than More than More than
Auditor :
90 points 85 points 80 points

Bad Poor Passable Good Excellent

Item Description Remarks
20 points 40 points 60 points 80 points 100 points

(Are step 1 to 3 operated and maintained)

- Are measures to control generating sources

Maintain and adequately maintained ?
Control -Are KAIZEN conditions of countermeasures against
source of ourbreaks that are clean?
- Are cleaning and oiling standards adequately
specified and utilized as required?

1point 2 point 3 point 4 piont 5 point

- Do leaders and circle members actively draw up one

point Lessons to upgrade skills?
1. Skill Training
- Have all members mastered the general inspection
skill?

- Are trained items correctly inspected?

2. General
- Have "Fuguai" Place been found by inspection?
inspection
- Have countermeasures been taken against found
"Fuguai Places?
- Have minor safety defects been found and have
3. Safety
counter-measures for them been taken?
- Check for leaks and oozing from piping and
equipment .

- Is equipment dustproof?

- Check for abnormal sound vibration of pumps and

motors . Check for beating sounds and offensive odor of
check valve ,solenoid valve etc.
- Are oil level and temperature of hydraulic units proper?
4. Line Audit
 Date MM Leader
Team
Name :
"Jishu - Hozen" Audit application Form & Sheet

Point Passed Not Passed

Equipment
No :
Acceptable Level = (Items 1 - 5
Step 4- 5 : General Inspection (Electric) level points)
Desired date of Audit :

Audit Date : Autonomous MM FM

Audit Autonomous MM FM
More than More than More than
Auditor :
90 points 85 points 80 points

Bad Poor Passable Good Excellent

Item Description Remarks
20 points 40 points 60 points 80 points 100 points

(Are step 1 to 3 operated and maintained)

- Are measures to control generating sources

adequately maintained ?
Maintain and Control
- Are improvement conditions of countermeasures
against source of outbreaks that are clean ?
- Are cleaning and oiling standards adequately
specified and utilized as required?

1point 2 point 3 point 4 piont 5 point

- Do leaders and circle members actively draw up

one point Lessons to upgrade skills?
1. Skill Training
- Have all members mastered the general
inspection skill?

- Are trained items correctly inspected?

2. General
- Have "Fuguai" place been found by inspection?
inspection
- Have countermeasures been taken against found
"Fuguai" places?
- Have minor safety defects been found and have
3. Safety
counter-measures for them been taken?
-Distribution control and operation panels have
indication name plates attached ?
-Are temperatures of distribution , control &
operation panels high ?
-Check dirtiness ( water , oil stains) of distribution,
control and operation panels
-Check for stains & damage on covers, packings
& filter of distribution, control & operation panels.