Jishu hozen

1Eight Steps in JISHU HOZEN

JISHU- HOZEN Prevent the occurrence of 1A/1B because of JH.

Reduce the OIL consumption by 50%.Reduce Process time by 50%.Increase use of JH by 50%

1. Prep of Employees2. Initial Cleanup of Machine

3. Take Counter Measures

4. Fix Tentative JH Stds5. General Inspection

6. Autonomous Inspection7. Standardization8. Autonomous Management

Prep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)

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JISHU- HOZEN

1. Initial Cleaning and Tagging

2. Counter Measures against Source & Kaizen

3. Develop Tentative Standards

Autonomous Maintenance7 steps

4. General Inspection5. Autonomous Inspection

6. Standardization7. Autonomous Management


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JISHU- HOZEN

1. Manage Model Team

2. Manage Model Machine

3. Implement 5S

Autonomous Maintenance

PROCESS

4. STEPS 123

5. Kickoff

6. Forms Autonomous Maintenance Teams

7. Steps 123 with Audits

8. Deployed to other M/C

9. Go to Step 4&5 and continue

1. Initial Cleaning and Tagging

2. Counter Measures against Source & Kaizen

3. Develop Tentative Standards4. General Inspection

5. Autonomous Inspection


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JISHU- HOZEN

4. Setup & Adjustment Loss

6. Defect Quality Loss

5. Yield Loss

WHY Autonomous Maintenance

7. Poor Skills of Operator

3. Breakdown Loss

1. Minor Stoppage Loss2. Reduced Speed Loss

8. Improper Position to Conduct Inspections

Preventive Maintenance

Production Maintenance

TPM

American Style of PMJapan Style of PM

Maintenance Departments Sole Responsibility

9. Confirmation of working conditions10. Daily Inspection / Periodical Inspection

10. Activities to prevent eqpt degradation

11. Activities to keep record on eqpt degradation

12. Keep cleaning, Inspection, Additional light

13. Activities to restore the machine conditions

14. Frequent Servicing, Solution of abnormality, Good Communication


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WHYJISHU- HOZEN

5. To eliminate equipment failure

6. To eliminate quality defect

2. To make operator familiar with his equipment

7. To eliminate cost losses

1 To establish basic equipment condition

3. To prevent equipment deterioration4. To maintain in optimal condition



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JISHU- HOZEN

1. Indl preserving one’s own eqpt

The Mind Set

2. Significant Change from early theory of “ I mfr - U Repair” or “ I make – U Fix”

Production indls Thoughts Maintenance indls Thoughts

Maint does NOT its Job Production do not know how to operate

Maint staff take took long to fix job We get lot of repairs so we don’t have ample to do a Real corrective and are forced to do only temporary jobThis eqpt is so OLD no wonder it breaks

down again & againWe are too busy to do vital daily checks We Prep the stds but they do not do the

checks

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JISHU- HOZENThree Key Tools for Autonomous Maintenance

Activity Board

One Point LessonMeetings

Key Concepts:Shop Floor Based ActivitiesOperator ConductedOperator EnhancingTeam Activity Autonomous ManagementTPM FoundationPart of the Job



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Activity Board

People Activity & Findings Treasures

Team & Team Mission Step1- initial Cleaning

Display Actual Findings from initial cleaning, such as Trash, Unnecessary Items, Dust and other contamination

Line Layout & identified important areas

-Definition-Pics before / after

Step 2- Source of Contamination“ Explain & show Focused Improvement activities for Source of Contamination”

-Safety Hazard- Contamination- Hard –to - Reach- Maint Failure

- Tag List Production/ Maintenance- Tag Movement / Actual tags

One Point Lesson


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Activity Board

Dept / Line: Bldg Y

Area: Bag Printer

Mach ID Date: 4/28 /14

Tag

Diagram No. Items Criteria Method Tools T(Min) Freq Person Resp


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One Point Lesson

One Point Lesson is a tool with the Following Characteristics:

1. One Sheet2. To Share the results of autonomous

study3. For 5-10 minutes

Contents can be knowledge and skills of

1. Equipment2. Safety3. Operation Process4. Task


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JISHU- HOZENEquipment

Deterioration

ACCELERATED Deterioration(Eliminate Cause)

Natural Deterioration(Extend Life Time)

Corrective MaintenancePrevent errors by IMPROVING Operability & Repair QualityImprove Maintainability & Repair QualityImprove Safety & Reliability

Establish Basic ConditionsCleaning : Eliminate all dust & DirtLubricating : Keep lubricants clean and replenished.Tightening: Keep Nuts & Bolts secure

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JISHU- HOZENClassification of Maint Activities

C. Activities to Rectify deteriorationBy improving reliability,

maintainability of machines (MTBF, MTTR)

A. Activities to prevent deteriorationBy correct operation , improvement of basic conditions & adjustments to prevent quality defects.

B. Activities to MEASURE deteriorationBy Senses (touch, see, hear, smell)

Role of Production Role of Maintenance

-Play vital role in A. also records maintenance data for prevention of recurrences of problems & MP design.- Play role in B by five senses-Play role in C by prompt reporting & assisting in sporadic failure.

-Play role in as a guide & educationist & providing help in identifying areas “ sources of problems & “Hard to Clean”- Play in role B by vibration & fluid analysis.- Play major role in C by improving MTBF, MTTR.-Besides that they maintain MIS , work for new equipment design & setup maintenance stds.


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JISHU- HOZENSTEP - 0

1. Prep a Cleaning & Lubrication Map

Initial Preparation

. Prep of JH Activities

2. Arrange Tools

3. Arrange Red & White Tags

4. History of Failures

5. Training on 7 Steps of Jishu Hozen

6. Gant Chart

7. Training on 7 Types of abnormalitiesPrep by Tanveer Ahmed, BE,ME Textile, MS/Mphil Quality Managements (Industrial Management)

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JISHU- HOZENSTEP - 1

2. Use 5 Senses for Cleaning

Initial Cleaning

1. Cleaning is Inspection

3. Find out 7 Types of Abnormalities

4. Put Tags on Abnormalities

5. Make the List of

Hard to CleanHard to LubricateHard to TightenHard to InspectHard to Adjust

Record cleaning timeCarryout Audit on 1st StepMeeting after the Daily ActivitiesRefers to the Old History Records



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JISHU- HOZENSTEP - 1 Initial Cleaning – 7 Types of Abnormalities

2. Places

In Accessible Unsafe

2. Sources

ContaminationQuality Defect

1. Items

Un-necessary – Non Urgent

1. Minor Flaws

1. Unfulfilled Basic Conditions


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1.Minor Flaws

Contamination

Damage

Adhesion

Abnormal Phenomenon

Blocking, Hardening, Accumulation of Debris, Peeling, Malfunction

Dust, Dirt, Powder, Oil, Grease , Rust, Paint

Play

Slackness

Bending, Cracking, Crushing, Chipping, Deformation

Shaking, Falling Out, Tilting, Eccentricity, Wear, Distortion, Corrosion

Belts, Chains

Unusual Noise, Overheating, Vibration, Strange Smells, Discoloration, Incorrect Pressure or Current


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2.Unfulfilled Basic Conditions

Lubrication

Lubrication Supply

Dirty, Insufficient, Unidentified, Unsuitable, Leaking

Oil Level Gauges

Tightening

Dirty, Damaged or deformed lubricant inlets, faulty lubricant pipes

Dirty, Damaged, Leaking, No indication of correct level.

Nuts and Bolts slackness, Missing, Cross-Threaded, Too long, Crushed, Corroded, Unsuitable washers, wing nuts on backward


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3. Inaccessible Places

Clean

ing

Chec

king

Adjus

tmen

t

Opera

tion

Position of Pressure Gauge, Thermometers, Flow Meters, Moisture Gauges, Vacuum Gauges etc.

Machine Construction, Covers, Layout, Footholds, Space

Lubr

icating

Tight

enin

g

Construction, Covers, Layout, Footholds, Instrument position and Orientation, Operating – Range Display

Position of Lubricant Inlet, Construction, Height, Footholds, Lubricant outlet, SpaceCovers, Construction, Layout size, Space

Machine Layout, Position of Valves, Switches and Leavers, Footholds


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4. Unsafe Places

Floors

Steps

Others

Lifting Devices

Special Substances, solvents, Toxic gases, Insulating materials, danger signs, protective clothing etc.

Unevenness, cracked, holes, projections, peeling, wear of steel chucker plates, slipping.

Lights

Rotating Machinery

Too steep, irregular, slipping, missing Hand rails

Dim, out of Position, dirty / broken covers,, no explosion proofing etcDisplaced, Fallen oil / broken covers, not safe for emergency, Missing emergency stop Devices

Wires, Hooks, Brakes & Other parts of cranes and Hoists


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5. Contamination Sources

Product

Raw Materials

Others

Liquids

Contamination by people & Forklifts, Infiltration through cracked walls, broken windows etc.

Leaks, Spills, Spurts, Scattering, Overflow

Lubricants

Gases

Leaks, Spills, Spurts, Scattering, Overflow

Leaking, Spills, Seeping Oils, Hydraulic Fluids, Fuel Oils

Leaking compressed air/gases/steam/vapors/exhaust fumes

Leaking Water/hot/cold, Half Finished Products, waste Water, Leaking Supply lines

Scrap Flashes, Cuttings, Packaging material and NC Products


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6. Quality Defect Sources

Foreign Matter

Shock

Viscosity

Concentration

Inadequate Warming, Heating, Compounding, Mixing, Evaporating, Stirring etc.

Dust, Rust, Powder, chips, Moisture, Wire scraps, Wood Pieces, Paper pieces, stones etc.

Moisture

Gain Size

Dropping, Jolting, Collision, Vibration etc.

Too little or Too Much, Infiltration

Abnormalities in Screens, Compressed air separators, Centrifugal Separators

Inadequate Warming, Heating, Compounding, Mixing, Evaporating, Stirring etc.


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7. Un-Necessary and Non Urgent Items

Machinery

Piping Equipment

Spare Parts

Jigs & Tools

Standby eqpt, spares, permanent stocks, Auxiliary material

Pumps, Fans, Compressors, Columns, Tanksers

Measuring Instruments

Electrical eqpt

Pipes, Hoses, Ducts, Valves, Dampers etc.

Temperatures, Pressure Gauges, Vacuum Gauges, Ammeters etc

Wiring, Piping, power leads, Switches, Plugs etc.

Gen Tools, Cutting Tools, Jigs, Molds, Dies, Frames etc.

Makeshift Repairs Tape, String, Wire, Metal plates etc.

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JISHU- HOZENSTEP - 2 Measure Against Sources

Counter Measure Against Source of Contamination & Hard to do CLRI

Ranking the priority places for daily cleaning

Counter Measure against source of contamination

Make approach easy for CLRI.

Make easy to do CLRI

Shorten, Cleaning & lubricating time.

Adopt concepts of localized guards.


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JISHU- HOZENSTEP - 3 Formulation of Cleanup and Lubrication Standards

Prepare Tentative Standards

Standards for Cleaning, Lubricating & Tightening

Standards are made by Operators themselves with guidance by PM

Standards are Made by using 5W 1h

Standards should be Easily understood by every one

Introduce Extensive Visual Control.



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Jishu hozen

Business

msmphil quality

hozenthree

problems amp

autonomous

play role

counter measures

industrial

vacuum gauges