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