TPM (Total Productive Maintenance) is a Maintenance Philosophy into the manufacturing process. TPM is A Culture A New Attitude
Productivity Increase due to OEE ( Overall Equipment Effectiveness ) improvement. Quality Improvement through Zero Defects. Cost Reduction through process improvement. Delivery Improvement through Breakdown reduction to zero. Safety, Health & Environment Improvement by zero accident and healthy working condition. Morale of the Employees will be improved through involvement and participation in TPM activities.
JISHU HOZEN STEP 1 7 Types of Abnormalities :1. Minor Flaws 2. Unfulfilled Basic Conditions 3. Hard to CLIT Area 4. Sources of Contamination 5. Unnecessary/Non urgent items 6. Sources of Quality contamination
Lubrication Insufficient, Dirty, Leaking, Unidentified Lubrication Supply Dirty, Damage, Insufficient, Faulty lubricant pipes Oil level gauges Dirty, Damaged, Leaking, No indication of correct level Tightening Nuts and Bolts slackness, Missing, Cross-threaded, Too long, Crushed, Corroded, Unsuitable washers
3. HARD TO CLIT AREA:Cleaning Machine construction , Covers, Layout, Footboards Lubrication Position of lubricant inlet, Construction, Inaccessible lubrication pipes
Inspection Operating range of pressure, Tools, Foundation bolts, Insufficient see through
Tightening Covers, Construction, Fixture Butting points Adjustment Position of pressure gauges, Flow meters , Temp. gauges
4. SOURCES OF CONTAMINATION :-
Compressed Air leakage from joints, cracks, broken pipes Lubricants Leakage, Over filling, Seepage Scrap Chips, Cast iron dust, Used lubricants, reject components Liquids Leaking water, Waste water, Leaking supply lines
Others Contaminants by people such as used clothes, Eatables, Biscuit wrappers
5. UNNECESSARY/NON URGENT ITEMS :Machinery Pumps, Fans, Compressors, Coolant tank Pipes Coolant pipes, Hoses, Valves, Attachments, Brackets Measuring Instruments Temperature & Pressure gauges, Ammeters Electrical equipments Switches, Wires, Plugs, Cables Jigs, Fixtures & Tools General tools, Cutting tools, Jigs, Fixtures Spare Parts Standby equipments, Obsolete materials Makeshift repairs Tape, unused nuts & bolts, metal plates, pipes & rods
6. SOURCES OF QUALITY CONTAMINATION :Foreign Matter Dust, Rust, Chips, Moisture, Paper pieces, Stones, Excess material Shock Dropping, Jolting, Collision, Vibrations Hot Weather Variation in bore size Moisture Compressed air mixed with water Fixture &Tools Low clamping pressure, Worn out locating pins, Jacks not working, Worn out tools Malfunction Sensors, limit switches, pressure regulators Human Error Inadequate butting & resting
Rotating Parts Spindle, Axes, Chips coming out of machine, Sharp corners Electrical Controls Naked wires, Uncovered circuits Floors Unevenness, Damaged, Oily Lights Dim, Out of position, No safety or Emergency stops Cranes Wire rope or chain worn out, Tackle welding broken or damaged Others Over inventory, Hot chips coming out of gaps or open doors
- 7 Steps of JH (Jishu Hozen) :JH0 Understanding equipment & Thorough Cleaning JH- 1 :- Initial Cleaning &Tagging. JH- 2 :- Implementing Countermeasures. JH- 3 :- Developing Tentative Standards for CLIT JH- 4 :- General Equipment Inspection ( Equipment Competent Operator ) JH- 5 :- General Inspection ( Process Competent Operator )
JH- 6 :- Standardization.
White and Red tagging done for countermeasures developed against a source of contamination, hard to access area for cleaning, lubricating, Inspection, tighten and adjust.
for CLIT
1.
2. Create visuals on machine 3. One Point lesson (OPLs) 4. Four Step audit
4. By acquiring this knowledge the operators are well aware of machine parts.
5. Various parts of the machine, their functioning and troubleshooting.
JH- 6 :- Standardisation
1. Kaizen and building mechanism for maintenance and management of autonomous inspection. 2. Eliminate Quality troubles and defects to expand activities to periphery of equipment. 3. Everybody should follow the work instructions strictly. 4. Necessary spares for equipments is planned and procured by maintenance.
2. PDCA (Plan, Do, Check and Act ) cycle must be implemented for Kaizens.