BACKGROUND SCENEBACKGROUND SCENE(MACHINE BUILDING DIVISION)(MACHINE BUILDING DIVISION)
Poor Equipment
Condition
Blame syndrome for breakdowns
“I operate you Maintain”
mentality
Dirty
Machine
Oil leakage
Dirty/oily floor
Scattered chipsLong Searching time
for tools/ tackles
Inadequate operator knowledge
about equipment
JISHU HOZEN STEP 1: INITIAL CLEANINGJISHU HOZEN STEP 1: INITIAL CLEANING
Identifying abnormalities through stratified fuguai tags: Interesting findings not known so far Changing Look of the machines: providing sense of pride to the workmen Increased awareness to identify: difficult to clean/lubricate/ inspect areas and the need for counter measures Specific tools developed in-house for cleaning difficult-to-access areas Spectrum covered small capacity welding machines to as big as 100 Ton – capacity machines, where each job goes on for months (to a size of 8.5 m components)
BEFOREBEFORE AFTERAFTER
FEEL GOOD CORNERFEEL GOOD CORNER
RESULTS OF STEP 1RESULTS OF STEP 1
More than 14000 fuguai tags identified and
attended In a span of about couple of years, 114 machines
were adopted for JH out of 147 machines Concept of doing JH in non-machine areas
introduced e.g. in fabrication/ assembly areas, sub-
stores.
TAG CLASSIFICATIONTAG CLASSIFICATION
BLUE BLUE & WHITE& WHITE : For Mechanical
GREENGREEN & WHITE & WHITE : For Electrical
BLACK & WHITEBLACK & WHITE : For Operator
Fuguai Age Analysis & Focus
NOS.NOS.
PERIODPERIOD
FUGUAI TAG STATISTICSFUGUAI TAG STATISTICS
JISHU HOZEN STEP 2 ACTIVITIESJISHU HOZEN STEP 2 ACTIVITIES
Countermeasures adopted for major problems responsible for making machines dirty
flying chips
oil leakage
oil coolant splashing
bird droppings and others
dirt/dust/slime
Innovative kaizens by workmen/supervisors
PROBLEMSPROBLEMS
BEFOREBEFORE
AFTERAFTER
COUNTERMEASURESCOUNTERMEASURES
RESULTS OF STEP 2RESULTS OF STEP 2
JH Kaizen done (Nos.) : 1227
One Point Lessons conducted (Nos.) : 699
Breakdown status (due to poor JH) [Hrs.) Reduction from 680 to 100
Oil consumption reduction (ltrs/month) From 1042 to 425
Noise level reduction (db) : From 125 to 80
Cleaning time reduction (average) From 60 to 10
[min/shift/machine]
Indirectly saving maintenance time (Hrs.) From 965 to 220
NOS.NOS.
PERIODPERIOD
JH OPL STATISTICSJH OPL STATISTICS
JISHU HOZEN STEP 3JISHU HOZEN STEP 3
Standardization for : CLIT
Colour codes and symbols
Lubrication and inspection check sheets
Greasing points marking
Markings on belts / pressure gauges
Oil level indicators
I-marking
Stickers for hands/eyes/arrows
Station concept with clockwise numbering system Cleaning time: Benchmark/ target/ achieving the minimum time and its standardization
Surrounding area upliftment
CLEANING TIME REDUCTIONCLEANING TIME REDUCTION
Time in Time in Mins/Shift/ Mins/Shift/
MachineMachine
PERIODPERIOD
STEP VII
STEP VI
STEP V
STEP IV
STEP III
STEP II
STEP I
STEPWISE STATISTICS OF MACHINES IN JISHU HOZEN(114 Machines)
04
23
05
77
05
0
0
TYPICAL NOVEL TECHNIQUESTYPICAL NOVEL TECHNIQUES
Red stickers on machine body for oil leakage (vigorous “dry “dry
floor”floor” campaign)
Pick up rounds by Managers
Metamorphosis amongst people (managers/staff/workmen)
through communications/ visits/contests/recognition
Displays/ slogans/ posters/ banners/ leaflets
Area of concern: Maintenance Dept. interaction with JH for skill
improvement Wanting