Training JH Pillar

8/11/2019 Training JH Pillar

1/41

JH

ACTIVITYT

P

M JISHU HOZEN

Presentation By : V.P.SINGH


2/41

TPM HISTORY

1. Developed by Seiichi Nakajima Vice

Chairman of the Japan Institute of Plant

Maintenance ( JIPM ) in Japan 1971

2. Introduction to TPM translated in to

English first time in 1988 ISBN NO-

915299-23-2 Productivity Press Inc.


3/41

What is Total Productive

MaintenanceTOTAL:

1.Maximization of total Efficency.

2.Entire life cycle of Production system

3.Covers of all departments & participation.

PRODUCTIVE:

1.Zero Defects

2.Zero Accident

3.Zero Breakdown

MAINTENANCE:

1.Covering the entire life cycle of production managementsystem.


4/41

TPM PolicyMicro turners

We at Micro turners Group are committed to adopt TPMfor achieving

Excellence

In our Business Operation through

Overall plant effectiveness leading to higher profitability Customer delight through zero defect, on time delivery

and prompt service

Prevention, reduction and elimination of all losses &wastage

Safe and healthy working environment, leading to highermorale

Culture of continual improvement


5/41

Benefits of TPM1.Increase productivity and OPE

OPE-Overall Plant Efficiency

2.Rectify customer complaints.

3.Reduce the manufacturing cost by 30%.

4.Satisfy the customers needs by 100%.

5.Reduce accidents.

6.Follow pollution control measures.

7.Higher confidence level among the employees.

8.Keep the work place clean ,neat & attractive.

9.Achieve goals by working as team.

10.Horizontaldeployment of a new concept in all areas of theorganization.

11.Share knowledge and experience.

12.The workers get a feeling of owning the machine.


6/41

OEE-Overall Equipment

EfficiencyO.E.E. = Availability X Performance rate X Qualityproducts rate

Availability = ( Loading hoursDowntime ) / Loading hours

Performance rate = Net utilization rate X Speed utilization rate

Net utilization rate = ( Output X Actual cycle time ) / ( Loading

hours-Downtime )

Speed utilization rate = Standard cycle time / Actual cycle time

Quality products rate = ( No. of quality products ) / Input volume

No. of quality products = Input volume( Startup defect volume +

No. of process defects + No. rework defects )


7/41

Step-O( Know your Machine )Step-1( Initial Cleaning )

Step-2( Countermeasures on sources of

contamination & easy to CLIRT )Step-3( Preparation to JH tentative standards )

Step-4( Knowledge & Skill for JH )

Step-5( Autonomous inspection )Step-6( Standardization )

Step-7( Autonomous management )

( Steps in JISHU HOZEN )


8/41


9/41

Types of Maintenance[ A ] Breakdown Maintenance

It means that people waits until equipment fails & repair it.[ B ] Preventive Maintenance

(a) Periodic Maintenance:

Time based maintenance and replacing parts to prevent suddenfailure and process problems.

(b) Predictive Maintenance:

It is conditions based maintenance.

(c) Corrective maintenance

Equipment with design weakness must be redesigned to improve

reliability or improving maintainability.(d) Maintenance Prevention

It indicates the design of a new equipment and are incorporatedbefore commissioning a new equipment.


10/41

Defects classification

A - Type defect B - Type defect C - Type defect

OK

OK

NOT OK

Action

taken by

operator

OK

OK

NOT OK

No actionby operator

LSL USLLSL USL

OK

OK

NOT OK

Actiontaken by

operator

LSL USL

The output is (OK) initially

Becomes (NG)

Corrective action is taken

by operator

Becomes (OK)

Use WhyWhy Analysis

The output is (OK) initially

Becomes (NG)

No action taken by

operator

Becomes (OK)

Use PM Analysis

The output is (NG) initially

Action taken by operator

Becomes (OK)

(setting scrap)

What is Defects


11/41

About Accidents

Two types of accidents1. Accident due to machine. Suddenly tool breakage

. Bolt loose. Belt loose

. Wrong tool use

2. Accident due to man. NO safety precautions

. Unfit for machine

. Unskilled for work


12/41

16 Major Losses1. Equipment failure loss

2. Setup and adjustment loss3. Tool change loss

4. Start-up loss

5. Minor stoppages loss

6. Reduce speed loss

7. Defect and rework loss8. Shutdown loss

9. Management loss

10. Motion loss

11. Line organization loss

12. Logistic loss13. Measurement loss

14. Yield loss

15. Energy loss

16. Die / Jig / Tool loss


13/41

222

Jishu-Hozen Step No.

Location of minor defects detected

Equipment name:

Control No.

Date of detection:

Detector:

Description of minor defects

This sheet should be attached to equipment

54321

TPM

Jishu-Hozen Step No.

Location of minor defects detected

Equipment name:

Control No.

Date of detection:

Detector:

Description of minor defects

This sheet should be attached to equipment

54321

TPM

About Tags


14/41

5 S System


15/41


16/41

1 S - Sheet

MICRO TURNERS List of Unnecessary items ( 1S sheet ) F / 5S / 01

Machine/ Cell / Area Description Supervisor / Area Owner :

S.No

.

Item

Description

(Material / Tool

/ Machine / Jigs

& Fixture /

Others)

Location

Reasons to

keep the

items

Period Qty.

Your

Suggestion for

Action

Final decision

taken by

management


17/41

2 S - Sheet

MICRO TURNERS List of Required tems ( 2S sheet ) F / 5S / 02

Machine/ Cell / Area Description Supervisor / Area Owner :

S.No

.

Description of

required items

(Material / Tool /

Machine / Jigs &

Fixture /Stationery &

Others)

Purpose to keep

the decided

items (Use)

Location

Qty.

Identificatio

n method

for items

RemarksMin. Max.


18/41

( JISHU HOZEN ) STEP 1 (


19/41

Difficult to clean, lubrication, inspection & retightening( CLIRT )

1. Cleaning inside not possible

2. Lubrication fill up facility not provided

3. Air pressure gauge not provided4. Hydraulic oil level not inspectionable

5. No facility provided bolt retightening

Activities / Records

Abnormalities List Out

Abnormalities Matrix

Tag Records

Team Formation

( JISHU HOZEN ) STEP1 (

Initial Cleaning )


20/41

List of Abnormality

JH ACTIVITY Abnormalities List outS.N. Name of Abnormality Classification Type of Tag

Responsibility

for put tag

Responsibility

for remove tag

Cleaning

1 Dirt C L I RT White Tag Operator Operator

2 Spillage C L I RT White Tag Operator Operator

3 Chipping C L I RT White Tag Operator Operator

4 Rusted C L I RT White Tag Operator Operator

5 Tool Kit & Instruments C L I RT White Tag Operator Operator

Lubrication

1 Lubrication map C L I RT White Tag Operator Operator

2 Spillage of oil C L I RT White Tag Operator Operator


21/41

List of AbnormalityInspection

1 Leakage C L I RT White Tag Operator Operator

2 Missing C L I RT White Tag Operator Operator

3 Tool / Bolt Wear C L I RT White Tag Operator Operator

4 Machine part Wear C L I RT Red Tag Operator Maintenance

5 Tool / Bolt Broken C L I RT White Tag Operator Operator

6 Machine part Broken C L I RT Red Tag Operator Maintenance

7 Bent C L I RT White Tag Operator Operator

8 Holes C L I RT White Tag Operator Operator9 Abnormal noise C L I RT Red Tag Operator Maintenance

10 Excess Heat C L I RT Red Tag Operator Maintenance

11 Vibration C L I RT Red Tag Operator Maintenance

12 Misaligned C L I RT Red Tag Operator Maintenance

13 Jammed C L I RT Red Tag Operator Maintenance

14 Cracked C L I RT Red Tag Operator Maintenance

15 Excess Play C L I RT Red Tag Operator Maintenance

16 Undressed wire C L I RT Red Tag Operator Maintenance

17 Pressure C L I RT Red Tag Operator Maintenance

18 Oil level C L I RT Red Tag Operator Maintenance

Retightening

19 Nut Bolt Loose C L I RT White Tag Operator Operator

20 Belt Loose C L I RT White Ta O erator O erator

( JISHU HOZEN ) STEP 2 (


22/41

( JISHU HOZEN ) STEP2 (

Change Machine )1. Countermeasures

. Sources of contamination are eliminated .. Eliminate guards easy to clean

. Eliminate guards easy to inspection hydraulic level

. Eliminate guards easy to inspection wires

2. Hard to access easy to clean, inspection, lubrications & retightening (CLIRT)

. Cleaning time less

. Dial provided to check air pressure

. Lubrication oil bottle provided near machine

. Marking on bolts for tightening

3. Eliminate abnormalities

. Easy to chips cleaning in side portion of machine. No jam chips conveyor

. Eliminate all leakages

4. Records

. List of countermeasure

. Photo before / after. KAIZEN for JH Activity


23/41

( JISHU HOZEN ) STEP 3( Tentative Standards )

1. Allow basic condition to be in place

2. Preparation Tentative Standards to maintain & control CLRT3. Developing the methods of visual controls

4. PM Points in JH Pillar

. Machining check sheet standard

5. QM Points in JH Pillar

. Chuck pressure

. Air pressure. Chuck run out

. Jaw face run out

. Feed

. Cutting speed

. R.P.M.

6. Safety Points JH PillarRECORD

1.CLIRT Time reduction time

2.PM points records

3.QM points records

4.NO. of accidents


24/41

Tentative Standard-01


25/41

Tentative Standard-01JISHU HOZEN INSPECTION STANDARD ( SCHEDULE )(Machine Front Side)

S.N. ITEM STANDARDFREQUE

NCYTOOL ACTION RESPONSIBILITY

A CLEANING STANDARD ( C )

1 All Front Covers NO Dust / Oil Daily Cloth Clean Operator

2 Material flow trolley NO Dust / Oil Daily Cloth Clean Operator

3 Operating Panel NO Dust / Oil Daily Cloth Clean Operator

4 Lubrication Unit NO Dust / Oil Daily Cloth Clean Operator

5Chuck, Jaws & Tool

EyeNO Dust / Oil Daily Cloth Clean Operator

6 Chips NO Chips Daily Magnet Clean Operator

7Tool, Gauges &

InstrumentsNO Dust / Oil Daily Cloth Clean Operator

8 Oil near M/C NO Oil Daily Cloth Clean Operator

B LUBRICATION STANDARD ( L )

1 Oil LabelSpecified level (

Green )Weekly Table Refill by Bottle Operator

2 Leakage NO Leakage Daily EyeInform to

Maint.Deptt. Operator


26/41

Tentative Standard-01C INSPECTION STANDARD ( I )

1 Working of Lub. Unit Working Daily EyeInform to

Maint.Deptt.Operator

2 Lubrication Motor No abnormal sound Daily Eear

Inform to


3 Chuck Jam Weekly Movement Greasing Operator

4 All Tool Loose / Wear Daily MovementRetighening /

ChangeOperator

5 Gauge / Instruments Control Plan Daily EyeInform to

SupervisorOperator

6 Material flow trolley No jumping of bearing Daily EyeInform to


7 Material flow trolley No breakage Daily EyeInform to

SupervisorOperator

8 Emergency Switch Working Daily EyeInform to


9 Push button switch (all) No breakage Daily EyeInform to


10 Air Pipe NO Leakage Daily EearInform to


11 Air Presser 5 to 6 kg / cm2 Daily EyeInform to


12 Air Gun NO Leakage Daily EearInform to


13 Chuck Pressure Daily Dial Indicator Reset Operator

14 Chuck Run out 0.01 m.m. Max. Weekly Dial Indicator Reset Operator

15 Turret Play No Play Weekly Eye

Inform to


15 Jaws/Stopper face run out 0.005 m.m. Max. Weekly Dial Indicator Reset Operator


27/41



28/41

Tentative Standard-02JISHU HOZEN INSPECTION STANDARD ( SCHEDULE )(Machine Back Side)

S.N. ITEM STANDARD FREQUENCY TOOL ACTIONRESPONSIBILIT

Y


1All Back Covers &

glassesNO Dust / Oil Daily Cloth Clean Operator

2 Chip Conveyor NO Dust / Oil Daily Cloth Clean Operator

3 Chip Conveyor Motor NO Dust / Oil Daily Cloth Clean Operator

4 Coolant Tank NO Dust / Oil Daily Cloth Clean Operator

5 Coolant Motor NO Dust / Oil Daily Cloth Clean Operator

6 Chips near M/C NO Chips Daily Magnet Clean Operator

7 Servo stabilizer NO Dust / Oil Daily Cloth Clean Operator


9 Chips Trolley NO Dust / Oil Daily Cloth Clean Operator

B CUTTING OIL STANDARD ( L )

1 Oil levelSpecified level (

Green )Daily TOP UP Refill Operator




29/41


C INSPECTION STANDARD ( I )

S.N. ITEM STANDARDFREQUENC

Y TOOL ACTIONRESPONSIBI

LITY

1Chips in Cutting Oil

TankNO Chips Daily Eye Clean Operator

2 Cutting Oil Motor No abnormal sound Daily EearInform to


3 Servo stabilizer O.K. Position Daily EyeInform to


4 Input Voltage 390 ~ 410 V Daily EyeInform to


5 Output Voltage 195 ~ 205 V Daily EyeInform to


6Chip Conveyor & Gear

Box

Abnormal Sound &

OverheatingDaily Eye

Inform to


7 Leakage of Cutting Oil NO Leakage Daily EyeInform to


8 Cooling Fan Running Daily EyeInform to


9 Small of Cutting Oil No Small Daily Eye Oil Change Operator

10 Air Pipe NO Leakage Daily Eear Inform toMaint.Deptt.

Operator


30/41



31/41

Tentative Standard-03JISHU HOZEN INSPECTION STANDARD (Machine Left Side)

S.

N

.

ITEM STANDARD FREQUENCY TOOL ACTION RESPONSIBILITY


1 All Side Covers & glasses NO Dust / Oil Daily Cloth Clean Operator

2 Hydraulic Power Pack NO Dust / Oil Daily Cloth Clean Operator

3 Fan Spindle MotorExhaust

NO Dust / Oil Daily Cloth Clean Operator

4 Fan Spindle Motor Inlet NO Dust / Oil Daily Cloth Clean Operator

5 Hydraulic Tank NO Dust / Oil Daily Cloth Clean Operator

6 Hydraulic Motor NO Dust / Oil Daily Cloth Clean Operator

7 Chips near M/C NO Chips Daily Magnet Clean Operator


9 Input Material Stand NO Dust / Oil Daily Cloth Clean Operator

B Hydraulic OIL STANDARD ( L )

1 Oil levelSpecified level

( Green )Daily TOP UP Refill Operator




32/41

Tentative Standard-03C INSPECTION STANDARD ( I )

S.N. ITEM STANDARD FREQUENCY TOOL ACTIONRESPONSIBI

LITY

1 Hydraulic Oil Motor No abnormal sound Daily EearInform to


2 Hydraulic Oil Motor No Overheating Daily HandInform to


3 Hydraulic Oil Pump No abnormal sound Daily EearInform to


4 Leakage of Hydraulic Oil NO Leakage Daily EyeInform to


5 Hydraulic Oil Pressure Specified on gauge Daily Eye

Inform to


6 Hydraulic PipeNo breakage /

LeakageDaily Eye

Inform to


7 Spindle Motor No abnormal sound Daily EyeInform to


8 Spindle Motor No Overheating Daily Hand Inform toMaint.Deptt.

Operator


33/41



34/41

Tentative Standard-04JISHU HOZEN INSPECTION STANDARD (Machine Right Side)

S.N. ITEM STANDARDFREQUE

NCYTOOL ACTION

RESPONSIBI

LITY


1 All Side Covers & glasses NO Dust / Oil Daily Cloth Clean Operator

2 Plastic Bin Stand NO Dust / Oil Daily Cloth Clean Operator

3 Plastic Bins NO Dust / Oil Daily Cloth Clean Operator

4 Chips No Scattered Daily Cloth Clean Operator

5 Coolant No Spillages Daily Cloth Clean Operator

6 Switch Board NO Dust / Oil Daily Cloth Clean Operator

B INSPECTION STANDARD ( I )

1 Switch Board No abnormal sound Daily EearInform to

Maint.Deptt.

Operator


35/41

PILLAR2 ( KAIZEN )Kai Change

Zen Good for betterKaizen Policy :

1. Concept of zero losses in every place

2. To achieve cost reduction targets in all resources

3. To improve overall plant equipment effectiveness

4. Extensive uses of PM analysis as a tool for eliminating losses

5. Focus of easy handling of operators

Kaizen Target :

Achieve & sustain zero losses with respect to minor stops,measurement and unavoidable downtimes.

Tool used in Kaizen :

1. PM analysis2. Why - Why analysis

3. Kaizen summary

4. Summary of losses

5. Kaizen register


36/41

PILLAR2 ( KAIZEN )

Purpose: Realize zero losses of all types, such as failure

losses and defect loses

Demonstrate ultimate production efficiency

improvement.Activates:

1. Understanding the 16 major losses

2. Calculating and setting goals for overall

equipment efficiency, productivity andproduction sustained

3. Implementation of PM analysis


37/41

Training Matrix

14

16

28

55

263

78

8

39

0

50

100

150

200

250

300

M/C

SYSTEM

JH

APRIL

MAY

JUNE

JULY

AUGUST

PILLAR 1 ( JISHU HOZEN ) STEP 4


38/41

PILLAR - 1 ( JISHU HOZEN ) STEP4( General Inspection )

1. Machine condition(a) Tentative standards are improved

(b) Kaizen are implemented

(c) TBM / CBM activates are planned

2.Educate the employees

(a) Knows possible improvements in JH standards(b) Aware of know why for important issues

(c) Know why why sheet

(d) The employees are trained in disciplines like Pneumatics,electrical, hydraulics, lubricant and coolant, drives, bolts, nuts &safety

3.Activities / Records(a) Preparation of inspection standards

(b) Training matrix

(c) Check list for general inspection



39/41

PILLAR - 1 ( JISHU HOZEN ) STEP5( Autonomous Inspection )

New methods of cleaning and lubricating are

used

Including good quality machine parts. This avoid

defects due to poor JH . Inspection that is made in preventive

maintenance is included in JH .

The frequency of cleanup and inspection is

reduced based on experience.



40/41

PILLAR - 1 ( JISHU HOZEN ) STEP6( Standardization )

Necessary items should be organized .

Work environment is modified such that

there is no difficulty in getting any item .

Everybody should follow the work

instructions strictly .

Necessary spares for equipments is

planned and procured .



41/41

PILLAR - 1 ( JISHU HOZEN ) STEP7( Autonomous Management )

OPE and OEE & others TPM targets must

be achieved by continuous improve

through Kaizen .

PDCA ( Plan, Do, Check & Act ) cycle

must be implemented for Kaizen .

Documents

Training JH Pillar