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JH

ACTIVITY
T
P
M JISHU HOZEN
Presentation By : V.P.SINGH
TPM HISTORY
1. Developed by Seiichi Nakajima Vice
Chairman of the Japan Institute of Plant
Maintenance ( JIPM ) in Japan 1971
2. Introduction to TPM translated in to
English first time in 1988 ISBN NO-
915299-23-2 Productivity Press Inc.

What is Total Productive
Maintenance
TOTAL:
1.Maximization of total Efficency.
2.Entire life cycle of Production system
3.Covers of all departments & participation.
PRODUCTIVE:
1.Zero Defects
2.Zero Accident
3.Zero Breakdown
MAINTENANCE:
1.Covering the entire life cycle of production management
system.
TPM Policy Micro turners
We at Micro turners Group are committed to adopt TPM
for achieving
Excellence
In our Business Operation through
Overall plant effectiveness leading to higher profitability
Customer delight through zero defect, on time delivery
and prompt service
Prevention, reduction and elimination of all losses &
wastage
Safe and healthy working environment, leading to higher
morale
Culture of continual improvement

Benefits of TPM
1.Increase productivity and OPE
OPE-Overall Plant Efficiency
2.Rectify customer complaints.
3.Reduce the manufacturing cost by 30%.
4.Satisfy the customers needs by 100%.
5.Reduce accidents.
6.Follow pollution control measures.
7.Higher confidence level among the employees.
8.Keep the work place clean ,neat & attractive.
9.Achieve goals by working as team.
10.Horizontaldeployment of a new concept in all areas of the
organization.
11.Share knowledge and experience.
12.The workers get a feeling of owning the machine.
OEE-Overall Equipment
Efficiency
O.E.E. = Availability X Performance rate X Quality products rate
Availability = ( Loading hours Downtime ) / Loading hours
Performance rate = Net utilization rate X Speed utilization rate
Net utilization rate = ( Output X Actual cycle time ) / ( Loading
hours-Downtime )
Speed utilization rate = Standard cycle time / Actual cycle time
Quality products rate = ( No. of quality products ) / Input volume
No. of quality products = Input volume ( Startup defect volume +
No. of process defects + No. rework defects )

Step-O ( Know your Machine )
Step-1 ( Initial Cleaning )
Step-2 ( Countermeasures on sources of
contamination & easy to CLIRT )
Step-3 ( Preparation to JH tentative standards )
Step-4 ( Knowledge & Skill for JH )
Step-5 ( Autonomous inspection )
Step-6 ( Standardization )
Step-7 ( Autonomous management )
( Steps in JISHU HOZEN )
( JISHU HOZEN ) STEP 0 (
Know your Machine )
1. Machine condition
. Past occurred defects
. Past happened accidents
. Past happened losses
2. Educate the employees
(a) Knows why JH, JH Aims, JH Targets & JH Steps.
(b) Knows Defects / Accidents / Losses
(c) Safety Instruction
(d) About 1s 2s
(e) About hydraulic circuit
(f) About pneumatic circuit
(g) About electrical control
(h) About electronic control
(i) About lubrication circuit
(j) About break-downs








Types of Maintenance
[ A ] Breakdown Maintenance
It means that people waits until equipment fails & repair it.
[ B ] Preventive Maintenance
(a) Periodic Maintenance:
Time based maintenance and replacing parts to prevent sudden
failure and process problems.
(b) Predictive Maintenance:
It is conditions based maintenance.
(c) Corrective maintenance
Equipment with design weakness must be redesigned to improve
reliability or improving maintainability.
(d) Maintenance Prevention
It indicates the design of a new equipment and are incorporated
before commissioning a new equipment.
Defects classification
A - Type defect B - Type defect C - Type defect
OK
OK
NOT OK
Action
taken by
operator
OK
OK
NOT OK
No action
by operator
LSL USL
LSL USL
OK
OK
NOT OK
Action
taken by
operator
LSL USL
The output is (OK) initially
Becomes (NG)
Corrective action is taken
by operator
Becomes (OK)
Use Why Why Analysis
The output is (OK) initially
Becomes (NG)
No action taken by
operator
Becomes (OK)
Use PM Analysis
The output is (NG) initially
Action taken by operator
Becomes (OK)
(setting scrap)
What is Defects
About Accidents
Two types of accidents
1. Accident due to machine
. Suddenly tool breakage
. Bolt loose
. Belt loose
. Wrong tool use
2. Accident due to man
. NO safety precautions
. Unfit for machine
. Unskilled for work
16 Major Losses
1. Equipment failure loss
2. Setup and adjustment loss
3. Tool change loss
4. Start-up loss
5. Minor stoppages loss
6. Reduce speed loss
7. Defect and rework loss
8. Shutdown loss
9. Management loss
10. Motion loss
11. Line organization loss
12. Logistic loss
13. Measurement loss
14. Yield loss
15. Energy loss
16. Die / Jig / Tool loss
222
Jishu-Hozen Step No.


Location of minor defects detected

Equipment name:
Control No.
Date of detection:
Detector:

Description of minor defects






This sheet should be attached to equipment
5 4 3 2 1
TPM
Jishu-Hozen Step No.


Location of minor defects detected


Equipment name:
Control No.
Date of detection:
Detector:

Description of minor defects






This sheet should be attached to equipment
5
4 3 2 1
TPM
About Tags
5 S System
5S System
S.N. Japanese Term English Translation
1 Seiri Short out
2 Seiton Systematized
3 Seiso Cleaning
4 Seiketsu Standardizations
5 Shitsuke Self Discipline
1 S - Sheet
MICRO TURNERS List of Unnecessary items ( 1S sheet )
F / 5S / 01
Machine/ Cell / Area Description Supervisor / Area Owner :
S.No
.
Item
Description
(Material / Tool
/ Machine / Jigs
& Fixture /
Others)
Location
Reasons to
keep the
items
Period Qty.
Your
Suggestion for
Action
Final decision
taken by
management











2 S - Sheet
MICRO TURNERS List of Required tems ( 2S sheet )
F / 5S / 02
Machine/ Cell / Area Description Supervisor / Area Owner :
S.No
.
Description of
required items
(Material / Tool /
Machine / Jigs &
Fixture /
Stationery &
Others)
Purpose to keep
the decided
items (Use)
Location
Qty.
Identificatio
n method
for items
Remarks
Min. Max.









Initial Cleaning
1. Arrange all items needed for cleaning .
2. After cleaning putting the tags.
. White tags is place where problems can be solved by
operator
. Red tags is placed where the aid of maintenance
department is needed
. Contents of tags is transferred to a register.
3. Tag matrix.
Identifying sources of contamination
1. Hydraulic oil level not visible
2. Inside cleaning of chips facility not available .
3. Inside wires not visible .







( JISHU HOZEN ) STEP 1 (
Initial Cleaning )
Difficult to clean, lubrication, inspection & retightening
( CLIRT )
1. Cleaning inside not possible
2. Lubrication fill up facility not provided
3. Air pressure gauge not provided
4. Hydraulic oil level not inspectionable
5. No facility provided bolt retightening
Activities / Records
Abnormalities List Out
Abnormalities Matrix
Tag Records
Team Formation




( JISHU HOZEN ) STEP 1 (
Initial Cleaning )
List of Abnormality


JH ACTIVITY
Abnormalities List out
S.N. Name of Abnormality Classification Type of Tag
Responsibility
for put tag
Responsibility
for remove tag
Cleaning

1 Dirt C L I RT White Tag Operator Operator
2 Spillage C L I RT White Tag Operator Operator
3 Chipping C L I RT White Tag Operator Operator
4 Rusted C L I RT White Tag Operator Operator
5 Tool Kit & Instruments C L I RT White Tag Operator Operator
Lubrication

1 Lubrication map C L I RT White Tag Operator Operator
2 Spillage of oil C L I RT White Tag Operator Operator
List of Abnormality

Inspection
1 Leakage C L I RT White Tag Operator Operator
2 Missing C L I RT White Tag Operator Operator
3 Tool / Bolt Wear C L I RT White Tag Operator Operator
4 Machine part Wear C L I RT Red Tag Operator Maintenance
5 Tool / Bolt Broken C L I RT White Tag Operator Operator
6 Machine part Broken C L I RT Red Tag Operator Maintenance
7 Bent C L I RT White Tag Operator Operator
8 Holes C L I RT White Tag Operator Operator
9 Abnormal noise C L I RT Red Tag Operator Maintenance
10 Excess Heat C L I RT Red Tag Operator Maintenance
11 Vibration C L I RT Red Tag Operator Maintenance
12 Misaligned C L I RT Red Tag Operator Maintenance
13 Jammed C L I RT Red Tag Operator Maintenance
14 Cracked C L I RT Red Tag Operator Maintenance
15 Excess Play C L I RT Red Tag Operator Maintenance
16 Undressed wire C L I RT Red Tag Operator Maintenance
17 Pressure C L I RT Red Tag Operator Maintenance
18 Oil level C L I RT Red Tag Operator Maintenance
Retightening
19 Nut Bolt Loose C L I RT White Tag Operator Operator
20 Belt Loose C L I RT White Tag Operator Operator




( JISHU HOZEN ) STEP 2 (
Change Machine )
1. Countermeasures
. Sources of contamination are eliminated .
. Eliminate guards easy to clean
. Eliminate guards easy to inspection hydraulic level
. Eliminate guards easy to inspection wires
2. Hard to access easy to clean, inspection, lubrications & retightening (
CLIRT)
. Cleaning time less
. Dial provided to check air pressure
. Lubrication oil bottle provided near machine
. Marking on bolts for tightening
3. Eliminate abnormalities
. Easy to chips cleaning in side portion of machine
. No jam chips conveyor
. Eliminate all leakages
4. Records
. List of countermeasure
. Photo before / after
. KAIZEN for JH Activity




( JISHU HOZEN ) STEP 3( Tentative Standards )

1. Allow basic condition to be in place
2. Preparation Tentative Standards to maintain & control CLRT
3. Developing the methods of visual controls
4. PM Points in JH Pillar
. Machining check sheet standard
5. QM Points in JH Pillar
. Chuck pressure
. Air pressure
. Chuck run out
. Jaw face run out
. Feed
. Cutting speed
. R.P.M.
6. Safety Points JH Pillar
RECORD
1.CLIRT Time reduction time
2.PM points records
3.QM points records
4.NO. of accidents






Tentative Standard-01
Tentative Standard-01
JISHU HOZEN INSPECTION STANDARD ( SCHEDULE )(Machine Front Side)
S.N. ITEM STANDARD
FREQUE
NCY
TOOL ACTION RESPONSIBILITY
A CLEANING STANDARD ( C )
1 All Front Covers NO Dust / Oil Daily Cloth Clean Operator
2 Material flow trolley NO Dust / Oil Daily Cloth Clean Operator
3 Operating Panel NO Dust / Oil Daily Cloth Clean Operator
4 Lubrication Unit NO Dust / Oil Daily Cloth Clean Operator
5
Chuck, Jaws & Tool
Eye
NO Dust / Oil Daily Cloth Clean Operator
6 Chips NO Chips Daily Magnet Clean Operator
7
Tool, Gauges &
Instruments
NO Dust / Oil Daily Cloth Clean Operator
8 Oil near M/C NO Oil Daily Cloth Clean Operator
B LUBRICATION STANDARD ( L )
1 Oil Label
Specified level (
Green )
Weekly Table Refill by Bottle Operator
2 Leakage NO Leakage Daily Eye
Inform to
Maint.Deptt.
Operator
Tentative Standard-01
C INSPECTION STANDARD ( I )
1 Working of Lub. Unit Working Daily Eye
Inform to
Maint.Deptt.
Operator
2 Lubrication Motor No abnormal sound Daily Eear
Inform to
Maint.Deptt.
Operator
3 Chuck Jam Weekly Movement Greasing Operator
4 All Tool Loose / Wear Daily Movement
Retighening /
Change
Operator
5 Gauge / Instruments Control Plan Daily Eye
Inform to
Supervisor
Operator
6 Material flow trolley No jumping of bearing Daily Eye
Inform to
Maint.Deptt.
Operator
7 Material flow trolley No breakage Daily Eye
Inform to
Supervisor
Operator
8 Emergency Switch Working Daily Eye
Inform to
Maint.Deptt.
Operator
9 Push button switch (all) No breakage Daily Eye
Inform to
Maint.Deptt.
Operator
10 Air Pipe NO Leakage Daily Eear
Inform to
Maint.Deptt.
Operator
11 Air Presser 5 to 6 kg / cm2 Daily Eye
Inform to
Maint.Deptt.
Operator
12 Air Gun NO Leakage Daily Eear
Inform to
Maint.Deptt.
Operator
13 Chuck Pressure Daily Dial Indicator Reset Operator
14 Chuck Run out 0.01 m.m. Max. Weekly Dial Indicator Reset Operator
15 Turret Play No Play Weekly Eye
Inform to
Maint.Deptt.
Operator
15 Jaws/Stopper face run out 0.005 m.m. Max. Weekly Dial Indicator Reset Operator
Tentative Standard-02
Tentative Standard-02
JISHU HOZEN INSPECTION STANDARD ( SCHEDULE )(Machine Back Side)
S.N. ITEM STANDARD FREQUENCY TOOL ACTION
RESPONSIBILIT
Y
A CLEANING STANDARD ( C )
1
All Back Covers &
glasses
NO Dust / Oil Daily Cloth Clean Operator
2 Chip Conveyor NO Dust / Oil Daily Cloth Clean Operator
3 Chip Conveyor Motor NO Dust / Oil Daily Cloth Clean Operator
4 Coolant Tank NO Dust / Oil Daily Cloth Clean Operator
5 Coolant Motor NO Dust / Oil Daily Cloth Clean Operator
6 Chips near M/C NO Chips Daily Magnet Clean Operator
7 Servo stabilizer NO Dust / Oil Daily Cloth Clean Operator
8 Oil near M/C NO Oil Daily Cloth Clean Operator
9 Chips Trolley NO Dust / Oil Daily Cloth Clean Operator
B CUTTING OIL STANDARD ( L )
1 Oil level
Specified level (
Green )
Daily TOP UP Refill Operator
2 Leakage NO Leakage Daily Eye
Inform to
Maint.Deptt.
Operator
Tentative Standard-02
C INSPECTION STANDARD ( I )
S.N. ITEM STANDARD
FREQUENC
Y
TOOL ACTION
RESPONSIBI
LITY
1
Chips in Cutting Oil
Tank
NO Chips Daily Eye Clean Operator
2 Cutting Oil Motor No abnormal sound Daily Eear
Inform to
Maint.Deptt.
Operator
3 Servo stabilizer O.K. Position Daily Eye
Inform to
Maint.Deptt.
Operator
4 Input Voltage 390 ~ 410 V Daily Eye
Inform to
Maint.Deptt.
Operator
5 Output Voltage 195 ~ 205 V Daily Eye
Inform to
Maint.Deptt.
Operator
6
Chip Conveyor & Gear
Box
Abnormal Sound &
Overheating
Daily Eye
Inform to
Maint.Deptt.
Operator
7 Leakage of Cutting Oil NO Leakage Daily Eye
Inform to
Maint.Deptt.
Operator
8 Cooling Fan Running Daily Eye
Inform to
Maint.Deptt.
Operator
9 Small of Cutting Oil No Small Daily Eye Oil Change Operator
10 Air Pipe NO Leakage Daily Eear
Inform to
Maint.Deptt.
Operator
Tentative Standard-03
Tentative Standard-03
JISHU HOZEN INSPECTION STANDARD (Machine Left Side)
S.
N
.
ITEM STANDARD FREQUENCY TOOL ACTION RESPONSIBILITY
A CLEANING STANDARD ( C )
1 All Side Covers & glasses NO Dust / Oil Daily Cloth Clean Operator
2 Hydraulic Power Pack NO Dust / Oil Daily Cloth Clean Operator
3
Fan Spindle Motor
Exhaust
NO Dust / Oil Daily Cloth Clean Operator
4 Fan Spindle Motor Inlet NO Dust / Oil Daily Cloth Clean Operator
5 Hydraulic Tank NO Dust / Oil Daily Cloth Clean Operator
6 Hydraulic Motor NO Dust / Oil Daily Cloth Clean Operator
7 Chips near M/C NO Chips Daily Magnet Clean Operator
8 Oil near M/C NO Oil Daily Cloth Clean Operator
9 Input Material Stand NO Dust / Oil Daily Cloth Clean Operator
B Hydraulic OIL STANDARD ( L )
1 Oil level
Specified level
( Green )
Daily TOP UP Refill Operator
2 Leakage NO Leakage Daily Eye
Inform to
Maint.Deptt.
Operator
Tentative Standard-03
C INSPECTION STANDARD ( I )
S.N. ITEM STANDARD FREQUENCY TOOL ACTION
RESPONSIBI
LITY
1 Hydraulic Oil Motor No abnormal sound Daily Eear
Inform to
Maint.Deptt.
Operator
2 Hydraulic Oil Motor No Overheating Daily Hand
Inform to
Maint.Deptt.
Operator
3 Hydraulic Oil Pump No abnormal sound Daily Eear
Inform to
Maint.Deptt.
Operator
4 Leakage of Hydraulic Oil NO Leakage Daily Eye
Inform to
Maint.Deptt.
Operator
5 Hydraulic Oil Pressure Specified on gauge Daily Eye
Inform to
Maint.Deptt.
Operator
6 Hydraulic Pipe
No breakage /
Leakage
Daily Eye
Inform to
Maint.Deptt.
Operator
7 Spindle Motor No abnormal sound Daily Eye
Inform to
Maint.Deptt.
Operator
8 Spindle Motor No Overheating Daily Hand
Inform to
Maint.Deptt.
Operator
Tentative Standard-04
Tentative Standard-04
JISHU HOZEN INSPECTION STANDARD (Machine Right Side)
S.N. ITEM STANDARD
FREQUE
NCY
TOOL ACTION
RESPONSIBI
LITY
A CLEANING STANDARD ( C )
1 All Side Covers & glasses NO Dust / Oil Daily Cloth Clean Operator
2 Plastic Bin Stand NO Dust / Oil Daily Cloth Clean Operator
3 Plastic Bins NO Dust / Oil Daily Cloth Clean Operator
4 Chips No Scattered Daily Cloth Clean Operator
5 Coolant No Spillages Daily Cloth Clean Operator
6 Switch Board NO Dust / Oil Daily Cloth Clean Operator
B INSPECTION STANDARD ( I )
1 Switch Board No abnormal sound Daily Eear
Inform to
Maint.Deptt.
Operator
PILLAR 2 ( KAIZEN )
Kai Change
Zen Good for better
Kaizen Policy :
1. Concept of zero losses in every place
2. To achieve cost reduction targets in all resources
3. To improve overall plant equipment effectiveness
4. Extensive uses of PM analysis as a tool for eliminating losses
5. Focus of easy handling of operators
Kaizen Target :
Achieve & sustain zero losses with respect to minor stops,
measurement and unavoidable downtimes.
Tool used in Kaizen :
1. PM analysis
2. Why - Why analysis
3. Kaizen summary
4. Summary of losses
5. Kaizen register
PILLAR 2 ( KAIZEN )
Purpose:
Realize zero losses of all types, such as failure
losses and defect loses
Demonstrate ultimate production efficiency
improvement.
Activates:
1. Understanding the 16 major losses
2. Calculating and setting goals for overall
equipment efficiency, productivity and
production sustained
3. Implementation of PM analysis

Training Matrix
14
16
28
55
263
78
8
39
0
50
100
150
200
250
300
M/C &
SYSTEM
JH
APRIL
MAY
JUNE
JULY
AUGUST
PILLAR - 1 ( JISHU HOZEN ) STEP 4
( General Inspection )
1. Machine condition
(a) Tentative standards are improved
(b) Kaizen are implemented
(c) TBM / CBM activates are planned
2.Educate the employees
(a) Knows possible improvements in JH standards
(b) Aware of know why for important issues
(c) Know why why sheet
(d) The employees are trained in disciplines like Pneumatics,
electrical, hydraulics, lubricant and coolant, drives, bolts, nuts &
safety
3. Activities / Records
(a) Preparation of inspection standards
(b) Training matrix
(c) Check list for general inspection



PILLAR - 1 ( JISHU HOZEN ) STEP 5
( Autonomous Inspection )
New methods of cleaning and lubricating are
used
Including good quality machine parts. This avoid
defects due to poor JH .
Inspection that is made in preventive
maintenance is included in JH .
The frequency of cleanup and inspection is
reduced based on experience .


PILLAR - 1 ( JISHU HOZEN ) STEP 6
( Standardization )
Necessary items should be organized .
Work environment is modified such that
there is no difficulty in getting any item .
Everybody should follow the work
instructions strictly .
Necessary spares for equipments is
planned and procured .

PILLAR - 1 ( JISHU HOZEN ) STEP 7
( Autonomous Management )
OPE and OEE & others TPM targets must
be achieved by continuous improve
through Kaizen .
PDCA ( Plan, Do, Check & Act ) cycle
must be implemented for Kaizen .