Jishu Hozen Notes

Jishu Hozen ActivitiesJishu Hozen StepsStep 1 - Initial Cleaning Step 5 – Autonomous InspectionStep 2 – Countermeasures against Sources of contamination Step 6 – Standardization

& Hard to access areasStep 3 – Preparing tentative standards Step 7 – Autonomous ManagementStep 4 - General inspectionStep 1 2 3 one set of steps. From step 4, quantum jump in level. After thorough step 4, go to step 5. Otherwise you falter in step 5.Implementation of Step 1 in part 1All Product units started Jishu Hozen step 1 activity. Kobetsu Kaizen sub committee classified machines into “A, B & C” rank. Jishu Hozen sub committee concentrated on “A” rank and few “B” rank machines for break down, defect, accident reduction & to increase the availability and reduce cost. Team of workmen and officers were involved in the initial cleaning. During cleaning, abnormalities were identified & tags were attached. Tags were classified into red & white, red tags are removed by the plant maintenance & white tags were rectified by Jishu Hozen team members.

Implementation of Step 2 in part 1Red and white fuguai were removed in Jishu Hozen Step2. Countermeasures were taken against the sources of contamination by providing localized guards, arresting leakages and horizontally deployed in all other areas.Countermeasures were taken against difficult to clean, lubricate and inspection areas, thus the Jishu Hozen activity time for cleaning, lubrication and inspection is reduced and machines remains clean without cleaning.

Implementation of Step 3 in part 1Tentative standards were prepared for Cleaning, Inspection & Lubrication. Following colour codes & symbols were developed for carrying out the activity & indicating its frequency.

Figure 5.3 Step 1 implementation

Step 1 implementation

Cleaning of Machine by team

Tag Identification

Classification of tags in Red & White

Prepare Tag matrix

Identification of source of contimination

Identification of Difficult to CLI

STEP 1

Step 2 Implementation

STEP 2

Countermeasures against fuguais

C ountermeasures against source of contamination

Countermeasures against hard to access areas for C LI

Step 3 Implementation

C reate tentative standards for CLI

Preparation of CLI check sheet

Implementation of visuals

Route map marking around the machine

STEP 3

Visuals are implemented on the machines for ease of inspection like marking of lubrication / hydraulic oil level, motor RPM direction, belt direction, oil tank colour coding, pipe line colour coding.

Activities under Part 2 To restore JISHU HOZEN activity, we developed ‘Dry Floor Steps 1, 2 & 3’ apart from the regular JIPM Steps.

Wider implementation

2

Jishu Hozen steps

STEP 1

STEP 2

STEP 3

DRY FLOOR STEP 1

DRY FLOOR STEP 2

DRY FLOOR STEP 3

STEP 4

STEP 5

STEP 6

STEP 7

Reversal

Basic Approach not ConsolidatedActivities restricted to only selected

manufacturing areas

Change visible on Equipment but no change in people

PART 1 PART 2

Activities with

Emphasis on

fundamentals for a

strong foundation

Machines = 646, Operators = 1986 Assy stages =39, Support function = 19 Jishu Hozen circles = 161

Machines = 406, Operators = 1020 Assy stages = 0, Support function = 0 Jishu Hozen circles = 0

Wider implementation of Jishu Hozen

A Rank M/C

100 %

C Rank M/C

0 %

Stores0 %

0 %

B Rank M/C

60 % 55 %

0 % AssemblyAreaInspection

Area

Maintenance

Operators

30 %PART - 1

JISHU HOZEN ACTIVITIESCOVERAGE

PART - 2J ISHU HOZEN ACTIVITIES

COVERAGE

100 %

Stores 100 %

100 %

100 %

100 %

AssemblyArea

InspectionArea

Maintenance

Operators B Rank M/C

100 %

C Rank M/C 100%

A Rank M/C100 %

Concept of Dry floor steps

S tan d ard co lo u r co d e sym b o ls .

D A IL Y W E E K L Y M O N T H L Y Q U A R T E R L Y

C LE A N IN G (B L A C K )

IN S P E C T IO N (O R A N G E )

LU B R IC A TIO N (B R O W N )

A C T IV ITY

Focus on Circle up gradation concept

Organization Chart & Circle formationAll equipment & all people are involved. Each circle was allocated multiple numbers of equipments. TPM organization

was formed consisting of Plant head, Unit heads, Product unit heads, and Module managers, Officers and Operators.

TPM is a system of overlapping circles. Equipment approach is not wrong. But equipment does not change on its own. It is the organization that owns it.

While forming the circle please keep organization in mind. Each circle ideally should contain 8 to 10 persons. Purpose is to groom the circle leader to do the work. No of equipment & No of persons should be balanced. In a circle you have circle leader and member.

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Activity Board

Circle Meeting

MY MACHINE CONCEPT MY CIRCLE CONCEPT

Jishu Hozen concept

Plant Head

Axle PU Body PU Engine PU Vehicle PU TMPUFoundry

PU

QA Maintene

nce

Manufact

uringStoresAssembly

Cell 1 Cell 2 Cell 3 Cell 4

Circle 1 Circle 2 Circle 3 Circle 4 Circ le 5 Circle 6

V. P. Manufacturing

PU Manager

Module Manager

Cell Leader

Circle Leaders

Organization Chart & Circle Formation


Dry floor step 1 implementation

Implementation of Dry floor steps at manufacturing shop

Activities for Dry Floor Step 1: Re- Initial Cleaning (IC)It is not just cleaning. We say cleaning is inspection. Cleaning time becomes zero only when your sources of contamination becomes zero.

IC means restoration of ignored equipment to bring to original condition. Your machine needs initial cleaning. Continue cleaning till sources of contamination become zero.

IC is to find fuguai

a) Functional cleaning - superficial cleaning no good. Only functional cleaning of the equipment helps in finding out fuguai. I do not want spic & span equipment. Ideally yes. Purpose is functional cleaning. When you do the manager model, uniform tells the story. Initially everyday m/c becomes dirty after cleaning of previous day. That takes you to step 2. You must do something.

b) Identification of sources of contamination & hard to access areas – this has to be done hard way, not by observation but by having folded arms. Ideas come when you get involved. So this is very important. Link with step 2. Textbook says source of contamination in step 2, but step 1 leads to step 2. More effort in step 1, better the step 2. In JH stagnation comes if step 1 not thorough.

Only with supervisors u can not change shop floor. JH circle need to be functionalIn Dry floor step 1 additional activities like daily manager round & 5 DON’T’S activities were introduced to strengthen

the Jishu Hozen circle activities. Fuguai classification is done to prioritize the fuguai removal.

5 Don’t on the Shop Floor:1. Don’t keep -Material/Jigs/ Tools/Measuring Instruments/Products directly on the shop floor/equipment.2. Don’t keep Material/Jigs/ Tools/Measuring Instruments/Products directly on the shop floor.3. Don’t write directly on machines/walls/doors etc.4. Don’t stick things directly on machines/walls/doors etc.5. Don’t take the temporary countermeasures

2 Do’s on the Shop Floor:Vicinity of Equipment:1) Fix position 2) Fix quantity

Excess must go out (Tools/Jigs/Material/Products/WIP)

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D ry flo o r ste p 1 D ry flo o r ste p 2 D ry flo o r ste p 3

5 D O N 'TS

C la ssific a t io n

o f 7 t y p e s o f

t a g s

M a n a g e r

ro u n d

S o u rc e s o f

c o n t a m in a t i

o n

Le a k a g e sE a sy t o

a c c e ss

C a p tu rin g

t h e lo sse s

Te n t a t iv e

st a n d a rd s fo r

C IL

V isu a ls

D ry flo o r p la n t

D ry flo o r sh o p sC irc le m e e t in g sA c t iv it y b o a rd O P L'S


Fuguai classification & Approach towards fuguaiIn Phase-II fuguai classification was done as follows for prioritizing the fuguai removal.

(Meant for JH circles – teach them)

How to identify which type of fuguai is it?

For this you always start from the right hand side as shown by the arrow. Let’s consider the example of screw missing at any point. By considering this you just think, can the screw missing cause unsafe condition? If the answer from this is yes than this fuguai belongs to unsafe point other wise ask the same question for unnecessary items. Is the missing screw unnecessary? If the answer is yes then classify the abnormality (Fuguai) in Unnecessary other wise ask the question -Is the missing screw causing quality defect? If the answer is yes then categorize it as quality defect other wise ask the next question. Same for other types also.

Suppose nut / bolt loose – you think deviation from basic condition. Don’t do that. Start from RHS. If any safety hazard due to loosening, it will fall under safety point. It may also fall under unwanted/unnecessary. Then remove.

5


Equipment Initial Cleaning

Fuguai Identification

Fuguai Classification

Fuguai Rectification

Daily Manager Round

5 Don’t's

Dry Floor Step 1

5 Don’t's 1) Don't keep Material on Shop

Floor

2) Don’t Keep Material

randmoly.

3) Don't write directly on

Machine, .Walls & Doors

4) Don't stick things directly

on.Machine ,Walls & Doors

5) Don't take temporary

counter .... .measures.

Fuguai Classification 1) Unsafe places

2) Unwanted / Slow moving

3) Quality defect

4) Hard to access

5) Sources of Contamination

6) Basic Condition

7) Minor defects.

Basic Condition

Source of Contaminat

ion

Hard to Access

Unsafe Point

Unnecessary

Quality Defect

Minor Defect

Found

Rectified

Put S No. Empty it every

day

Put S. no. EMPTY IT EVERY DAY

If there is some quality problem, it could be under quality defect. It was loose because it was hard to access. Suppose chips falling due to loosening then source of contamination. If it falls under one condition, stop. If it does not fall under any of six condition then under minor defect. Bolt/nut generally basic condition. One Point LessonsOne Point Lessons are imparted to JISHU HOZEN Circle members for

- Basic Knowledge: Points that must be known- Improvement Cases: Point that prevents the recurrence of troubles- Trouble Cases : Points of improvement concept / method leading to positive results

Activities for Dry floor Step 2: Kaizen/Countermeasures for contamination/Leak free & Easy to access equipment

Reduction of C L I time is key parameter. Sum up these through Kaizen example sheet / OPL (generated thru CLI reduction)

Normally machine cleaning of 15 hours/man/month is required. Only then machine changes. Particularly for manager model. If manager model > 20 hours but no perceptible change then they are losing time somewhere. Some team good change in 10 hours. Learn from them. For step 3, less time required.Fuguai removal is done as per the priority of Fuguai classification. To achieve & sustain leakage free equipment, the following approach is used:

(I)Arresting Sources of Contamination

Sources of Contamination:Chips, Oil, Sand, Dust, Coolant, Humidity, Noise, fumes/ smoke, sputters, water/air leakage, spray, oil soaked water, paint sludge, steam, people etc.

Identify all sources of contamination. Even the product can be a source of contamination. In sugar factory sugar itself can be a contaminant. Dropping of product should not happen.

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One Point Lesson

Trouble CasesImprovement CasesBasic Knowledge

One point Lesson

Dry floor step 2 approach

Dry Floor Step 2

Contamination Free Equipment

Reduction of

Contaminant

Generation

Localising the

Contaminant

Elimination of

Contaminants

Leakage Free Equipment

Provision of

Guards to arrest

splashes of Oil &

Coolant

Modification of

Pressure/Directio

n of Oil/Coolant

Conversion of

Flexible Hoses to

Permanent

Metallic Pipes

Difficult to Access

Relocation of

element

Rerouting of

pipes / cables

Modification of

guards,

platforms &

ladders

Dry floor Step 3 implementation

Put S No. Empty it every

day


Kobetsu Kaizen teams consisting of manufacturing, improvement cell, maintenance were formed to help Jishu Hozen to

eliminate Source of contamination. Countermeasures against source of contaminations were taken by applying the

methodology to contain the source of contamination.

Oil leakage- in principle- eliminate it. If not possible (rare), minimize it wherever it involves high cost.

Collection – If leakage from top, put it close to source. Don’t come straight to collection. Don’t provide huge collection pan. Put a visual control mark.

If you do that, you’ll know lesser or more than previous day. Then why why.

I saw very big collection pan & almost full. That will not do. Follow this approach.

Contaminants wise action plan was prepared to arrest the source of contamination

(II) Leakage Free Equipment To achieve the leakage free equipment Elimination, Minimization, Localization of the contaminant was done.

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Source of contamination reduction

C hip s

Use of

loc a lised

gua rd s

Design

c ha nge

Red uc tion

in

ma c hining

stoc k

Red uc tion

of c h ip size

b y c utting

tool a ngle

mod ific a ti

C o llec tion

of c hip s b y

using tra ys,

c hutes,

tro llies

O il / C oo la nt

Use o f

c ollec tion

tra ys

O p timisa ti

on of

d irec tion &

p ressure

Provision

loc a lised

gua rd s

Proc ess

c ha nge

from w et

to d ry

c utting

O p timisa ti

on o f

c oo la nt

flow

Sa nd

Use of

gua rd s a t

d isc ha rge

end o f

c onveyors

Sea ling of

op enings

in sa nd

c onveying

system

Provision o f

skirting on

c onveyors

Use of d ust

extra c tion

system a t

genera tion

p o ints

c onveyors

b e lt w id th

inc rea sed

to 800 mm

from 550

Provision o f

trollies to

c o llec t

sp illed

sa nd

W orn out

d ie surfa c e

rec ond itio

ning

Actions for source of contamination

Actions for leakage free equipments

Leakage Free Equipment

Modification of

Pressure/Direction

of Oil/Coolant

Relocation of

oil / lubricant

nozzles

Optimisation of

pressure of oil /

lubricants

Relocation of

coolant,

lubricant tanks

Provision of

Guards to arrest

splashes of Oil &

Coolant

Use of guards

with collection

trays

Use of guards

with collecting

ducts

Use of localised

guards

Conversion of

Flexible Hoses to

Permanent

Metallic Pipes

Use of sealants

for fittings

Reduction of

extra length

pipes

Hose pipes

rerouting with

rigd clamping


Minimize

Can I

eliminate

the source?

Collec

Localize

Methodology to contain the source of contaminationPut S No.

Empty it every day


III. Activities for Hard to Access areaHard to Access Areas means:

Difficult to lubricateDifficult to inspectDifficult to cleanDifficult to retightenDifficult to operateJH is not only for maintenance of machine but also for operation of it. Even set up /adjustment comes under it.

Counter measures against Hard to access areas for cleaning, Lubrication, Inspection and retightening are Identified and

Rectified.

Activities for Dry Floor Step 3 – Preparing Tentative Standards for Contaminant/Leakage free equipment

With the help of Planned Maintenance & Machine manuals, Tentative Cleaning, Lubrication and Inspection

standards, check-sheets & route maps are developed by operators for daily Cleaning, Lubrication, Inspection &

re-tightening.

For each of these (C L I) a set of three required.

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Visuals For CLI

Dry Floor Step 3

Tentative Standars

Route Map CILCheck Sheet

Cleaning Daily

Cleaning Weekly

Cleaning Monthly

Inspection Daily

Inspection Weekly

Inspection Monthly

Lubrication Daily

Lubrication Weekly

Lubrication Monthly Right hand part

Left hand part

Electrical control panel

Machine columnBlow

plate lifter

Hydraulic

power

pack

1

4

6

Hydraulic valve

74

5

2

3

Situated on platform

Easy to access for cleaning

Modification of

platforms

Removal of unwanted / big guards

Re routing of pipes /

cables

Esay to access for Inspection

Implementation of visuals

Relocation of

lubricating units

Relocation of gauges

Provision of ladders / stair case

Hard to access

Easy to access for Lubrication

Relocation of

lubricating units

Rerouting of pipping

Modification of filling

caps

Use of plain conduit

inplace of spiral

Cleaning Lubrication Inspection1.Tentative standard

2.Checksheet

3.Route map

You don’t carry standard all the time. Standard is for understanding. Check sheet is for filling up.

Step 3 also visual Control.

If oil level green, ok but if always in green, same level, then not ok.

It must go down otherwise it is not functioning.

When you teach operators to see oil level, tell them to monitor if it is going down or not. Only mechanical checking will not do. Visual control help you to certain extent but you need to bring ingenious ideas in that.

If fan is moving or not seeing that is enough. Go a step further, ball, how high it is flying, whether flow enough. Do such ingenious ideas. This reflects on your activity.

Minor StoppagesLoss is generated when equipment stops for less than 15 minutes & machine component is not replaced.Capturing Minor Stoppages, incidents have been done by the JISHU HOZEN Circle members to improve performance rating & OEE.Counter Measures are taken by the JISHU HOZEN circle members to reduce Minor Stoppages. Step 4 activities – General InspectionIn step 4 we aim to understand the structure, functions & principles of the equipment & to study its ideal state, to seek the

utmost improvement in the efficiency of equipment. Aim to inspect all constituent mechanisms & parts of the equipment,

without exception, with the eye of an “operator skillful with equipment”. In training modules are prepared to enhance the

skill & knowledge of circle members. There are 6 sub steps:

4.1 Nut & Bolt

4.2 Drives

4.3 Lubrication

4.4 Pneumatics

4.5 Hydraulics

4.6 Electrical & Electronics

The sequence is important. There are 2 parts of step 4 for implementations as

shown here.

These training manuals will be created by E & T. Actual implementation by JH.

Thus 2 pillars are involved

Methodology of step 4 implementation

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RGR

paper Fan

Actual Implementation of General Inspection

Education on General Inspection

Manual

Self Audit (90%).

Manager Audit (85%)

Top Mgt. Audit (80%)

Next Sub Step

Education on General

InspectionLeaders

ok

NG

Leader to Circle

member

GeneralInspection

Rectification/Kaizen for fuguais

Revision ofStd/ check sheet.

Understanding thru test

New things will get added. Make correction in hand.

Summary

Teach what kind of fuguais can be present. Set of OPLs required.

Summary of Results:

e.g. How many nuts and bolts together for inspection? How many fuguais identified. Categorize them e.g. Nuts and bolts rusty, without washer, missing etc and review tentative standards created so far. Use red colour for wrong check point. Include new items in red. Remove / cross points as applicable. In step 5 these standards get converted into final standard.

Most important are tentative standard and check sheet. After education & training ,further changes are required.

Content wise step 4 fuguai has to be much deeper. In step 4 many many new fuguai will come to light. Till step 3 emphasis was on 5 senses and not on education & training. Now education & training and review of standards / check-sheets / route-maps and the same need to be updated in step 4.

It is a good idea to plot the number of corrected standards (C L I ) against sub steps of step 4.

Step 5:You have tentative standard + check sheet + maps corrected in step 4. In step 5, Combined final standard as against one standard/check sheet/route map for each of C L I.

JH Implementation at Assembly lineStep 1 Activities -Initial Cleaning

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During initial cleaning waste, stain marks & dust are removed. Arrangement of Shelves, boxes, worktables, tools & Jigs

are done. Fuguai’s were identified and rectified.Slow moving, unwanted objects are identified and removed from the area.

Storage place for non confirmative parts are provided. Visual controls are implemented.

Step 2 Activities - Countermeasures against Sources of Contamination & Difficult to access

Counter measures are taken against

sources of contamination, for moving

heavy objects, for elimination of

operations involving bending,

stretching, and turning of body & to

reduce the time required for counting

parts. Placement of tools in such a

way that double handling/Inspection

eliminated by introduction of easy to

pick tools, ease of use of Jigs, Tools.

First In First Out for parts is started.

Step 3 Activities – Creation of Tentative standards

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Assy Step 2 implementation

Countermeasures against bending , stretching & turning

STEP 2

Reduce time required for counting of parts

Eliminate double handling & inspection of parts

First in first out for parts

Poka Yoke to reduce defects

Storage place for removed packing materials

Countermeasures for moving heavy objects


Removal of waste,stain marks & dust

STEP 1

Arrangement of shelves, boxes,work table, tools & Jigs

Identification & removal of unwanted & slowmoving objects

Provision of area for non confirming parts

Implementation of displays

Identification & rectification of fuguais

Thrust given on implementation of cleaning, Inspection & Lubrication standards, and Visual controls implementation on assembly stages .By implementation of visual controls non value added activities like searching, counting & confirmation of

parts were eliminated. Reduction of losses like set up & adjustment is carried out.

STEP – 4: General Inspection4-1 : Jigs & Tools used in Assembly4-2 : Measuring Instruments4-3 : Online Inspection4-4 : Devices used in Assembly Line4-5 : Operability / Sustainability

STEP – 5: Line BalancingSTEP – 6: Autonomous Control

3 treasures of JH:1. Meeting

2. Activity board

3. OPL

JISHU HOZEN CIRCLE ACTIVITY STATUS

Unit Cell

Circle

Name

Step 1

Step 2

Step 3

Dry Floor Plant Step 4Step 5Ste

p 1Step 2

Step 3 4.1 4.2 4.3 4.4

4.5

4.6

Axle

PU

Pinion Cell

Date of passing

One circle in charge of multiple machines. Criteria for passing some machine –individual audit- when all equipments pass, circle passes.

Data Required for JH:1. Activity Time on JH Circles.

• TOTAL Activity TIME.• Activity Time per person(Avg.)

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Tentative standards for C IL

C IL time reduction

Implementation of Visual Controls

Eliminintation of counting, searching, confirmation of parts by visual

Review of work standards

Review of setup & adjustement

STEP 3

By Experience, 15 hours/person /month required. change comes visible.Distribution of time is also important. 20 minutes are not enough for functional cleaning. Additional cleaning say 2 Hrs at a time required for thorough Cleaning. 20 minutes they may or may not work. 2hrsx 3, 4hrs× 1, you can have for concentrated JH in addition to daily 20 minutes.

2. No. of Fuguais DETECTED & RESOLVED • 7 Classification of Fuguais • RED & WHITE tags.

Conversion of RED to WHITE TAGS3. Sources of Contamination4. OEE Data (compilation by KK)

• Loss DATA• Minor stoppage

5. One Point LESSON SHEETS6. No. OF KAIZEN EXAMPLE SHEETS7. No. of DI FFICULT to ACCESS AREAS DETECTED & RESOLVED.

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Documents

Jishu Hozen Notes