TPM

TPM
JISHU
JISHU HOZEN
HOZEN
By
By

Sudhansu
Sudhansu Bhushan
Bhushan Mohapatra
Mohapatra
TPM
TPM Consultant
Consultant –– IIPM
IIPM
E-mail
E-mail :: sbm@iipm.ac.in
sbm@iipm.ac.in
FOUR STEPS TO ACHIEVE JH
STEP 0 Understanding the equipment.
STEP 1 Initial cleaning & abnormality
identification.
STEP 2 Abnormality rectification &
eliminating hard to access area.
STEP 3 Preparation of tentative “ CLTI”
standards
 STEP 0
This is a preparatory step, which deals with making people aware of the
adverse effects of forced deterioration.

Major problem(1)

Medium problem(30)

Minor problems(300)

Invisible problems(3000)

Heienrich triangle.
 STEP 0
Understanding the equipment
1. Draw single line diagram to know
function of all parts and sub assemblies
2. To understand safety requirements
associated with the equipment.
3. Understand why forced deterioration is
caused and the losses due to this
4. To provide one point lesson in all unsafe
condition and in skill required for CLTI.
Draw single line diagram to know function of all parts
and sub assemblies

Oh my god another Time saved and we can easily understand

breakdown, go and bring
drawing from the drawing
the equipment and its sub assemblies.
office

Time delay to bring drawing from office

To understand safety requirements associated
with the equipment.
Do not touch
electrical
parts with wet
hands
 One point lesson
ONE POINT LESSON
Theme No.
PART & TYPE OF BEARING IN Date of
ID FAN preparation
Classification Section Chief Group Prepared
Basic Improvement Trouble chief Clerk leader By
Knowledge Cases Cases

Bearing used in ID Fan is ball bearing type which consist

of inner race ,outer race ,rolling element ( ball )and cage .
Figure show the bearing used in our fan
CAGE

INNER RACE

BALL

OUTER RACE
 STEP 1
Initial cleaning

Prepare a cleaning plan.

Thorough cleaning of the equipment and
the surrounding.
List out the abnormality and put a red tag
near the equipment.
Prepare cleaning plan and thoroughly clean the
equipment and the surrounding.
List out the abnormality and put a red tag near the
equipment.

Abnormal Abnormal
temperatur smell
e

Abnormal
vibration

leakages
List out the abnormality and put a red tag near the
equipment.

Abnormal Abnormal
temperatur smell
e

Abnormal
vibration

leakages

Go near the equipment and put red tags on the abnormalities found.
 STEP 2
Countermeasure for the cause of forced
deterioration and improving hard to access areas

This step is to eliminate the sources that

generates the contaminations (dirt stains etc.)
and to improve the areas hard to access for
cleaning, lubrication and maintaining the
allocated time.

This step generates lots of kaizens developed

by the TPM members.
Examples of countermeasure against Source of
contamination

Before After
Countermeasure against hard to access areas

Before After
 Kaizen made for hard to clean area

Before After
 Preparation of tentative “ CLTI ” standards
First understand the requirement of the operator and
whether the present standard is meeting his requirement. If
it is not then take the action to develop a new cleaning,
inspection and lubrication standard for the same.
In consultation with the operators and the maintenance
crew, prepare a plan for cleaning, oiling and retightening of
the equipment parts, including the time required. After
these things are finalized the leader should assign the
responsibility to the different people.
After this CLTI calendar to be filled.
 Come up with better ideas of all

Decide places for cleaning, lubrication, tightening

and inspection (CLTI).
Cleaning
Lubrication
Tightening
Inspection
Abnormal sound
Vibration / Temperature
Burning smell
Make a schedule and plan for the same

CLIT CALENDAR
 Pressure gauge marking

Before After
Oil level marking for better inspection

Before After
Points marked on retightening parts
CLTI marking and direction of rotation marking

Before After
 Open and close marked on the equipment

After marking we can easily tell whether open or closed

 Open and close marked on the equipment

Proper identification of lubricant and container

No identification of lubricant and container

Checks to be performed during normal working hours

Hmm
everythin
g is fine
 VALVE KEPT CLOSED IN OPERATION

MATCHED MIS-MATCHED
 C-1

C-4
C-3
C-2
VT PUMP-1

L-2.1

L-1

I-5

I-2
I-1

I-3 I-4
Examples of visual controls implemented for easy
inspection (BLOWER AREA)
A blower is having three valves, these valves are painted in three
different colors for easy identification.

Outlet valve Inlet Valve By-pass Valve

BLOWER CASING OIL PRESSURE GAUGE

EXAMPLE OF VISUAL MANAGEMENT -WIRE ROD MILL -STAND 1 , 2 , 3

Stand
Stand--33 Pressure
Pressuregauges
gauges

DDCC
Bevel
Bevelgear
gearbox
box
Motor
Motor
 Visual Management
TILL STEP-4 IN STEP-5

V-Belt rotation was not Transparent V belt guard

visible due to existing provided & visual
cover management achieved
 Before
Before

After
After

Initial cleaning at Example of Fuguai Countermeasure against Source of Contaminati

Stand no - 1 in Stand no-1 of Hard to access area -stand Water splashing at sta
Wire Rod Mill area of Wire Rod Mill of WRM
 Example
Example- -Visualisation
VisualisationofofInspection
InspectionPoint
Point

Oil flow meters are Pressure gauge range

installed to ensure marking for easy
correct quantity of oil inspection
flow inside the
Bearing temperature monoblock with range
monitoring of all marking
blower at a single
panel
Example
ExampleofofVisual
Visualcontrol
controlImplemented
Implementedfor
forEasy
EasyInspection
Inspection

Lubricator scale
marked for easy
inspection
JISHU HOZEN

ICL VISHNUPURAM
Step -1 Initial cleaning
Step -1 Initial cleaning & abnormality listing
Step -1 Initial cleaning & abnormality listing
We are
We are responsible
responsible of
of our
our equipment
equipment

Jishu Hozen chairman TPM Chief Coordinator

TPM coordinator
Kiln Team Leader
KILN MAINDRIVE

BEFORE AFTER
KILN MAINDRIVE

BEFORE AFTER
STEP3 – CLTI MARKING VISUALISATION

BEFORE AFTER
STEP3 – CLTI MARKING VISUALISATION

BEFORE AFTER
STEP3 – CLTI MARKING VISUALISATION
BEFORE AFTER
STEP 3 – CLTI MARKING

BEFORE AFTER
STEP 3 – CLTI MARKING

BEFORE AFTER
STEP 3 – CLTI MARKING

BEFORE AFTER
STEP 3 – CLTI MARKING

BEFORE BEFORE
 CLTI in Kiln-1 main drive area

BEFORE AFTER
 CLTI in Kiln-1 main drive area

BEFORE AFTER
CLTI in Kiln-1 main drive area
BEFORE AFTER
Finally conduct Audits and confirm
the proper implementation of the
standards