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Discover to Discover

Cleaning with Meaning

Cleaning without cleaning

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Why TPM ?

Why JH

Approach

Financial Impact

Back ground

Aim

Abnormalities

Improvements &

Kaizen

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Profit

Lo

sses

or

Ab

s.

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Forced Deterioration

Loss

Time

Per

form

ance

Natural Deterioration

Time

Per

form

ance

Point of JH

Profit in loss

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Total Profit Management

Business model

Creating Leadership

Resulting in Reduction of Mfg. Cost

TPM

Total people movement

Non-business model

Creating Ownership

Resulting Reduction of BAD

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Step - I Step - II Step - III

Cost

Occ

urr

ence

s

JH Steps

Break down

Defect

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8

Machine found with leakage of oil , coolant, air and burr spillage in and around

Frequent stoppages are found to be more , since machine is very old.

No ownership in machine cleanliness which detoriates machine basic condition.

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Machine top

LM Guide ways

Hydraulic Motor fan

Tool Magazine

AIM

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5. Defect Sources –

Burr accumulation near Limit

6.Unecessary & non urgent items –

Centre placed near gauge

7. Unsafe places –

Motor gear rotating without cover

1. Minor Flaws –

Door Glass in broken condition

2.Unfulfilled Basic Condition -

Clamping pad missing

3.Source Of contamination -

Dust enters hole

4.Hard to access –

Difficult to remove Coolant cover

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Baniyan

Waste

Nylon brush

I found we remove

≤ 48 - hr

Red Tag

I found I remove

≤ 24 - hr

White Tag

Goggles

Lengthy

brush

Spray Gun

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Monday

Machine Base & Spindle head

Tuesday

Coolant Tank & Hydraulic tank

Wednesday

Machine Left Side & Right Side

Thursday

Coolant motors & Magazine Covers

Friday

Machine inside – right & left

Saturday

Machine outer & Burr Trolley

Daily Machine Cleaning Schedule

BEFORE AFTER BEFORE AFTER

BEFORE AFTER BEFORE AFTER

Spindle Motor Coolant Tank

Tool Magazine Hydraulic Motor

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BEFORE AFTER

Burr Accumulation during machining

Over telescopic Guard

burrs

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Burr Accumulation removed during

telescopic movement

Difficult to inspect conveyor chain condition Easy to inspect conveyor chain condition

Provided with

Acrylic sheet

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BEFORE AFTER

Before After

Result:

Auto Program for cleaning of fixture

Analysis:

Operator Fatigue Eliminated.

Manual element is more

Benefits:

Manual cleaning of fixture

17

1.51

0

10

20

Before After

Min

Cleaning time

TPM Secretary : Pillar Chairman : Kaizen Done By :

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Reduce Manual Element

Idea :

S.NO C L I TREQ STANDARD

(value/qty)

HOW TO

DO

(Method)

WHAT

TOOL

TO USE

1 H1 Reservoir P No Dust

2 H2 Radiator fins P No Dust

3 H3Direction Control

valveP No Dust

4 H4Oil Level

indicationP Min or Max

5 H5 Pressure gauge P35 to 40

Kg/cm²

6 H6 Hydraulic motor P No Noise

7 H7Hydraulic pump

jointsP No Oil Leak

CLIT STANDARD - JH STEP 3

Hyd

raul

ic U

nit

AREA & PHOTOGRAPH LOCATION

H1

H4

H5

H2

H7H3

H6

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18

Thank you

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