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Autonomous Maintenance

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Focussed Improvement

2
Planned Maintenance

3
Quality Maintenance

4
Office TPM

5 6 7 8 9

Tool Maintenance

Initial flow Control

Education & Training

Safety, Health & environment

Jishu Hozen autonomous Maintenance

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

Members:

1. Operators 2. Line leaders 3. supervisors

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

7. Autonomous Management 6. standardisation 5. Autonomous Inspection

4. General Inspection
3. Tentative standards

2. Counter Measures
1. Initial Clean up
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Jishu - Hozen
Steps for developing
1. Initial Cleaning (inspection) All- around clean-up of dust and dirt on equipment. Oiling and re-tightening of bolts and nuts Finding and restoration of Fuguai (abnormalities)

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Purpose of cleaning

So Cleaning isESSENTIAL

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DIS COVER

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DISCOVER

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WHAT TO CHECK

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

Jishu Hozen 7 Steps

Step 1: Initial Clean up
a. b. c. d. Formation of JH circles division of machine pars to operators Training on abnormality identification Preparation of red & white tags a. White tags for abnormality that can be corrected by unskilled person b. Red tags for abnormality that can be corrected by skilled person Keeping cleaning tools ready fixing time for JH Activity Cleaning all parts of the machine even opening of parts are necessary Inspection of parts during cleaning activity Identification and tagging of abnormality and recording Identify difficult to access areas around the machine-In-Accessible(IA) Identify the SOC source of contamination after cleaning Record in the matrix red & white tags,IA,SOC

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

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Tools used for cleaning

Baniyan waste
To clean small burr & coolant

Nylon brush
To clean small burr & coolant

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Tools used for cleaning

Wire brush
To clean small burr & coolant

Spanners
To tighten loose bolts & nuts

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Tools used for cleaning

Showel
To clean big burr & swarf

Screw drivers
To tighten loose screws

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Tools used for cleaning

Allen Keys
To remove screws

Allen Keys
To remove hard/ solidified burr & dust

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Jishu Hozen 7 Steps

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

Machine Parts: 1 2 3 4 5 6

Responsibility:

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Jishu Hozen 7 Steps

Step 1: Initial Clean up
Record in the matrix red & white tags,IA,SOC
Tag Matrix
Machine No: Circle No: Slno M/c Parts dust 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
R P

Leak

Loose

Missing vibration noise

Broken

Wornout nonStd

others

total

P = Tags put

R= Tags Removed

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Jishu Hozen 7 Steps

Step 1: Initial Clean up
Record in the matrix red & white tags,IA,SOC
source Why Why why Why countermeasure Source of Contaminantion slno contaminant 1 2 3 4 5 6 7

InAccessible /difficult to Clean,Lubricate,Inspect,Re-tighten - CLIR slno Area 1 2 3 4 5 6 7 CLIR Why Why why Why countermeasure

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Jishu Hozen 7 Steps

Step 1: Initial Clean up
Countermeasure Plan for Red/white/IA/SOC slno 1 2 3 4 5 6 7 8
Tags linked to losses No of tags 25 20 15 10 5 0 Failure S etup Yield Defect Motion

abnormality

Action Plan

Tgt Dt

Resp

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Jishu - Hozen
Steps for developing
2.

Countermeasure s for sources of problems and difficult places

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

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Jishu Hozen 7 Steps

Step 2: Countermeasures for SOC/IA/others
a. b. c. d. e. f. g. Taking actions on all abnormalities eliminating difficult to access areas Eliminating SOC Machine CLEAN Without Cleaning status Various kaizens implemented Machine ready for tentative standard preparation Step2 audit passed
Tags Put Vs Removed - cumulative for HSL9
No of tags 250 200 150 100 50 0 Aug-04 Sep-04 Oct-04 Nov-04 Dec-04 Jan-05

Tags put

Tags removed

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

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JH 2nd Step
Before Easy to lubricate After

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JH 2nd step
Easy to inspect and adjust Before After

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

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

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Jishu Hozen 7 Steps

Step 3: Preparation of Tentative standards
a. b. c. d. e. f. g. h. Making a list of Cleaning, Lubrication,Inspection & Re-tigthening points arriving at method and frequency of CLIR dividing the CLIR into mahine zones Preparation of standards chart with visual aids Education of operators on standards Practising the standards for minimum 1 month Update new check points Have step 3 audit Passes

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Jishu Hozen 7 Steps

Step 3: Preparation of Tentative standards
JH Tentative Checksheets MONTH :
SL NO M/C STATUS
RUNNING STOPPED
RUNNING
STOPPED

M/C NO :
ACTION IF ABNORMA L

TIME (SEC)

FREQ

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

CLEANING
1.1Clean front side of machine

Dy Wk

60 Oper 300 Oper

1.2 Clean burrs in bed

1.5.Clean coolant tank

Dy

60 oper

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

Dy Dy Dy Dy Daily Daily Daily Daily Daily

10 Oper Top up oil 10 Oper Top up oil Inform supervisor Inform 10 Oper supervisor Inform 30 Oper supervisor 10 Oper 30 Oper Inform supervisor 30 Oper Inform supervisor 10 Oper Inform supervisor 10 Oper Inform supervisor

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ACTIVITY

HOW

RESP

DATE

Jishu - Hozen
Steps for developing
4. Overall Inspection Training in check-up skills through checkup manuals. Find and restore slight defects through general inspection.

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Jishu Hozen 7 Steps

Step 4: Preparation of General Inspection
JH Step 4 Training
Topics
Sl No. Emp. No. Name M/c No Bolts & Nuts Pneumatics Hydraulics Electrical Drives Fits/toler ances Safety Process condition

10

11

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TVS-SUZUKI Tpm.training

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Jishu - Hozen
Steps for developing
5. Autonomous Inspection Formulation and implementation of cleanup and oiling lubricate criteria and autonomous inspection check sheet which can be performed efficiently and positively.

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Jishu - Hozen
Steps for developing
6. Standardization Standardize various types of field management items. Establish the system to thoroughly maintain and control them.
Establish logistics standard Standardization of data records Standardization of die, tool and jig management Process quality assurance standard, etc.
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Jishu - Hozen
Steps for developing
7. Autonomous Management
Continue to develop corporate policy and commitment target and conduct Kaizen activities regularly, and record the data analyzed through MTBF to improve the equipment.

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TPM Vs initiatives at Wada

Double E initiatives Quality Initiatives comm. scrap Meas.Pri cust.Co Vendor eff redn d/t redn nt mpl. Dev. RTY Imp COQ HMP Projects sixsigma

TPM

GMP

Spares. Tool.Imp M/c Imp Mgmt Projects

1 2 3 4

KK JH QM PM

5 Otpm 6 7 8 E&T SHE Ifc

9 Ttpm

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