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(Step 0-3)
1
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AUTONOMOUS MAINTENANCE
Kinerja
FI
Standard
PMForcedDeterioration
2
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JISHU HOZENJISHU HOZEN
PENGERTIAN
Pemeliharaan mandiri adalah kegiatan dimana
set iap karyawan melaksanakan tugas-tugas
harian pada peralatannya sendiri yang
mel iput i inspeks i, pelumasan, penggantian
komponen, reparasi, mengatasi gangguan, uji
akurasi, dll dengan tujuan agar kondisi
peralatan dapat dijaga sendiri kondisinya oleh
si pengguna.
Saya menjalankan,
Anda membenarkanSaya menjalankan,
Saya membenarkan
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TujuanTujuan Program AMProgram AM
Tujuan program AM adalah:
benar dan pengecekan harian
membawa peralatan kepada kondisi idealnya melalui
restoration (pengembalian ke keadaan semula) dan proper
management (manajemen yg sesuai)
peralatan terpelihara dengan baik
Tujuan penting lainnya adalah untuk Perubahan Cara Kerja
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Step (Tahapan) AM
STEP. 6 Standardization (Buat standard yg Baku)
STEP. 7 All Out Autonomous Management
STEP. 4 General Inspection
(Standarisasi alat, Lingkungan kerja & proses kerja)
STEP. 5 Autonomous Inspection
(Lakukan Inspeksi langkah S1-4 lagi)
STEP. 2 Counter measures for causes of deterioration & hard to access area
(Mencarari sumber masalah, Hilangkan sumber & buat pembersihan mudah)
STEP . 3 Tentative Standard (Buatkan Standard sementara)
.
STEP. 0 Preparation (Persiapan)5
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PengertianPengertian AM : Cara lainAM : Cara lain melihatnyamelihatnya..
Step 0
Persiapan
untuk sang bayi
Step 7 Mempersiapkan bayi
untuk tantangan
Step 6 Baby logbook
Step 1
Pembersihan awalKunjungan rutin
Step 2
Mencari sumber masalah/
area yang sulit di akses
Step 5
Berbagi tang-
Step 4
Meningkatkan pengetahuan! Step 3
gung jawab!
harus dilakukan/di-
inpeksivacc
ines
6
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PengertianPengertian AM: Cara lainAM: Cara lain melihatnyamelihatnya..
Bay Orang tua Do ter
OperatorMesin Teknisi7
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The Three Crown Jewels of
8
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TigaTiga MahkotaMahkota AMAM
3 Mahkota AM:
Activity Boards (Papan Circle)
-
Team Meetings (Circle Meeting)
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Story Board Autonomous MaintenanceStory Board Autonomous Maintenance
Nama Tim & Anggota Master Plan Pabrik Daftar Tag
Defect
No. of OPL
Defect
OPLCLI Time act vs Std
ep
Tanggung Jawab
Area/Mesin
Master Plan TimSafety Safety
Graph
Peta/Gambar
1. ----------------
Section Policy Graph
Jadwal aktivitas AM Sumber
pengotor
Sumber
pengotor
Standar Antara
2. ----------------
3. ----------------
--------------------
Team Policy
Issues:
No. of Tag
Defect kritis
y u
diakses
Defect kritis
y u
diaksesDaftar
CLI std,
procedure
Target
------------------Policy:
Graph
KAIZEN
10
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Story BoardStory Board Factory Master PlanFactory Master Plan
2001 2002AM Step 01 02 ---- Month --- 12 01 02 ----------
-
-2
-3-4
-5
-6
-7
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Story BoardStory Board -- Team Master PlanTeam Master Plan
2001
Line 01 02 03 04 05 06 07 ----- Month -----A Step-1
-
Step-3
----------------------------------
B Step-1
Step-2
Step-3-----------------
-----------------
12
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Story BoardStory Board -- AM Activity TimeAM Activity Time
Waktu
100
120 menurun dan rasio waktuimprovement harus meningkat
dengan aktivitas AM.
80
Meeting
40
Cleaning
0
20
an Feb Mar A r Ma Tar et
13
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Story BoardStory Board -- No. of TagNo. of Tag
400No. of Tag No. of
Tag onKemam uan O erator:
300
350
Mampu menemukan defect
200
250
100
150.
Tag off
Kemampuan Operator:
0
Jan Feb Mar Apr May Target
14
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Story BoardStory Board -- Cleaning Time IncreasingCleaning Time Increasing
AM Activity Time100
40
50
60
70
80
90 Meeting
Improvement
0
10
20
30
Jan Mar
CleaningNo. of Tag on: Meningkat
80
100
120
No. of Tag
Ketersediaan operator mene-
20
40
60
Tag on
0
Jan Mar
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Story BoardStory Board -- List of Tag: SafetyList of Tag: Safety
Line Name:Daftar Bahaya
Team Name:
No. Location Description Date Countermeasure Request to Name Deadline Completed
Equipment:
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Story BoardStory Board -- List of Tag: Source of DirtList of Tag: Source of Dirt
Line Name:
Equipment:
Team Name:
No. Location Description Date Countermeasure Request to Name Deadline Completed
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Story BoardStory Board -- List of Tag: Hard to AccessList of Tag: Hard to Access
Line Name:
a tar area yang su t ang au
Team Name:
No. Location Description Date Countermeasure Request to Name Deadline Completed
Equipment:
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Story BoardStory Board -- List of Tag: Critical DefectList of Tag: Critical Defect
Line Name:Team Name:
No. Location Description Date Countermeasure Request to Name Deadline Completed
Equipment:
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Story BoardStory Board -- No. of One Point LessonNo. of One Point Lesson
No. of OPL
140
160
100
120mprovemen
Safety
Defect
40
60
0
20
an Feb Mar A r Ma Tar et
20
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Story BoardStory Board -- Imprevement SheetImprevement Sheet
Line Name:
Lembar Improvement
Date:
Before After
Equipment: Team Name:
Comment: Comment:
Benefit: 21
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Story BoardStory Board -- Cleaning/Inspection/LublicationCleaning/Inspection/Lublication
TimeTime
Time
v as yang a u an un u men apa an re- en a ve an ar .
Bagaimana menurunkan waktu
1. Eliminasi sumber pengotor120
140 LublicationInspection
Cleaning
. m nas area yg su a ses
3. Manajemen visual80
100
.
5. Standardisasi
6. Automatisasi20
40
0Jan
Feb
Mar
Apr
May
Step-3
8 am/hari/shift x 60 mnt = 480 mnt/hari/shiftTarget:
10 menit 480 mnt x 2% = 9.6 mnt
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Story BoardStory Board -- Tentative StandardTentative Standard
Pre-Tentative Standard digunakan dari step dan dimodifikasi
selama step . Kemudian Tentative Standard (standar antara)
arus uat pa a step .
Selama o erasi/tidakBagaimana
L o c a t i o n S t a n d a r d W h e n H o w M e t h o d T i m e P e r i o d
- - - - - - - - - - - - - - - - - - - - - -
- - - - - - - - - - -C l e a n i n g- - - - - - - - - - -
Kondisi yg benarBerapa lama
- - - - - - - - - - -
- - - - - - - - - - -L u b r i c a t io n
- - - - - - - - - - -
- - - - - - - - - - - -
- - - - - - - - - - -
D r a w i n g
I n s p e c t i o n
- - - - - - - - - - -
Prosedur, apabila kondisi tdk benar
Gambar tangan, 3D, detailoperas s , am a an o om s
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One Point LessonOne Point Lesson
-
1. Basic knowledge
2. Troubleshooting
3. Improvement
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ContohContoh OneOne Point LessonPoint Lesson
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ContohContoh OneOne Point LessonPoint Lesson
Visual Control Valve Hopper bisa dilihat jelas, bila
valve membuka maka alatnya bergerak seolah
memompa liquid dari Buffer & bila liquid
mencapai maximum, valve menutup maka alatnya
Tanggal Pelaksanaan
Nama
Tanda Tangan
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Meetings
27
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AUTONOMOUS MAINTENANCE
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JISHU HOZENJISHU HOZEN
Di step 1 diterapkan motto Pembersihan
adalah inspeksi dalam prakteknya.
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JISHU HOZENJISHU HOZEN -- Step 1Step 1
TUJUAN
- Mencegah kerusakan yang disebabkan debu dan kerak
-
Personil
- Menyentuh peralatan mengembangkan rasa memiliki terhadap peralatan
- Melatih mata untuk mendeteksi fuguai dari peralatan
- Mempelajari fungsi dan struktur dari peralatan- Mengetahui titik lemah dari peralatan
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JISHU HOZENJISHU HOZEN -- Step 1Step 1
Pembersihan adalah inspeksi
Hal-hal yg penting untuk diperhatikan:
- Nomer satu pengamanan
- Operator melakukan sendiri pembersihan sebagai pekerjaan
normal
- Bersihkan semua kotoran yg telah menumpuk bertahun-tahun
- Buka tutup-tutup yg belum pernah dibuka dan bersihkano oran- o oran yg menempe
- Bersihkan kotoran tdk hanya dari peralatan itu sendir i, tetapi
juga dari peralatan transfer, kotak-kotak/panel-panel listrik,
tanki-tanki fluida yg ada di dalam dan peralatan bantu lainnya- Jangan putus asa jika peralatan cepat kotor kembali setelah
dibersihkan. Perhatikan sebera a ce at kotorn a kembali dari
mana dan bagaimana terjadinya.
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JISHU HOZENJISHU HOZEN -- Step1Step1
Pembesihan
Pengecekan Menemukan abnormality
Efek Positive
Kebanggaan Rasa memiliki
Tanggung JawabDisiplin
Kebiasaan Perilaku Budaya
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PEMBERSIHAN ADALAH INSPEKSI
Membersihkan alat secara menyeluruh
bagian dari peralatan
Normal? atau
Abnormal?
Identifikasi area
yg sulit dibersihkan
Mendeteksi bagian yang
rusak dari peralatan
Sumber kontaminasi
Yg terlihat
Daftar sumberDaftar area
kontaminasia ar area yg su a ar per anyaan
yg defektif
Cacat yg tersembunyi menjadi nampak
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REDUCE CLEANING TIME
ELIMINATE YES ATTACKINGDIRT
COUNTER
MEASURES
FOR
HTC
NO REDUCE YES
NO CONTAIN YESGUARDS
NO SCREEN YES
NO DIRECTFAN/CHIMNEY
PAN/TRAY
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TPM TPM
Step No: 1 2 3 4 5 6 7
ABNORMALITY
Step No: 1 2 3 4 5 6 7
ABNORMALITY
Control No:
Date Found:
Found by:
Equipment:
Control/PK No:
Date Found:
Description of Abnormality:
Description of Abnormality:
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JISHU HOZEN - TAG COUNT
TYPES OF FUGUAIS TYPE TYPE TYPE TYPE TYPE TYPE TYPE TOTAL
1 2 3 4 5 6 7 TAGS
DUST LOOSE MISSING HOLES EXCESS NOISE HARD TO PERFORM OTHERS ATTACHED
DIRT CHATTERING WEAR EXCESS HEAT JH ACTIVITY
SPILLAGE ECCENTRIC CHIPPED ODOUR
LEAKAGE INCLINED BENT DISCOLOURATION
SCRATCH VIBRATING BROKEN
RUST EXCESS MOMENT DENTED
SPLASH
LOCATION OF FUGUAI
, ,
OF EQUIPMENT WIRINGS,VALVES,3-POINT
SET,ETC
DOORS/INSIDE OF SAFETY COVER,OPERATION/
COVERS CONTROL PANEL,INSPECTION
HOLE,ETC
ASSOCIATED WORING OIL,LUBRICATION
EQUIPMENTS TANK,HYDRAULIC UNIT
ETC
PERIPHERAL MEASURING INSTRUMENT,JIGS
EQUIPMENTS WORKING TABLES, TOOLS,
ETC
TRANSPORTATION CHUTE,CONVEYORS,
,
AROUND EQUIPMENT FLOOR.PIT, WALL, CEILINGS
ETC
INSIDE MACHINE AND GEARS,CAMS,CHAINS,SHAFT
MACHINE PARTS PULLEYS,SPROKETS,ETC
TOTAL TAGS ATTACHED
TOTAL TAGS DETACHED
36
Step 1Step 1 Master PlanMaster Plan
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Step 1Step 1 -- Master PlanMaster Plan
Activi ty Month 1 Month 2 Month 3 Month 4 Month 5
n a sa on o s ep n a c ean ng
2 Tagging on machine(With the knowledge of
different categories.viz. Safety,Minor defect etc.
.
4 Resolution of Tags attached.
5 Meeting of circle
6 Identifying the Hard to access/clean& lubricate
area. Also difficult to inspect area.
7 Preparation of OPL
8 Audi ts for compl etion of step no.1
Start of activity Finish of activity Sustain activity
Activi ty inprocess
HLL - Silvassa Beverages37
St 1 I iti l Cl i A ti itiSt 1 I iti l Cl i A ti iti
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Step 1: Initial Cleaning ActivitiesStep 1: Initial Cleaning Activities
e ore
Cleaning focused at eliminating Long
Deposited Contaminations
Com lete Partici ation from Circle
Teams and Line Management
Basic awareness provided to the
Objectives
38
Step 1:Step 1: Daftar FuguaiDaftar Fuguai
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Step 1:Step 1: Daftar FuguaiDaftar Fuguai
IdentifikasiFuguai
Diskusi Tag
Pembuatan Pembuatan
Diskusi dengan
tim engineering
Eliminasi
Update
progres ke
tim circle
OPL;
Logging of
Result;
Know-Why
ag a zen ugua s an ar
Tag dikonversi
menjadi kaizen
39
ApaApa ituitu ""FuguaiFuguai"?"?
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ApaApa ituitu FuguaiFuguai ??
Fuguai = deviasi (penyimpangan)
- Kegagalan fungsi
-
- Sulit untuk diakses / observasi
- Susah diperiksa- a aman
In Association withIn Association with40
P b ihP b ih d l hd l h i k ii k i t b ikt b ik!!
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PembersihanPembersihan adalahadalah inspeksiinspeksi yangyang terbaikterbaik!!
In Association withIn Association with
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BagaimanaBagaimana mengenalimengenali ""FuguaiFuguai"?"?
Meggunakan 5 indra:
Lihat --> menggunakan mata untuk mengobservasi
Dengar --> mendengarkan dan mencoba meng-
Cium --> mencoba mengenali bau yang aneh
Sentuh --> mencoba merasakan panas, vibrasi Rasa --> secara normal tdk direkomendasikan,
tapi kadang2 dapat dilakukan dgn hati2
Menggunakan otak: Berpikir sebelum membuat keputusan!
In Association withIn Association with
42
5 INDRA5 INDRA
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5 INDRA5 INDRA
In Association withIn Association with
43
BagaimanaBagaimana menemukanmenemukan ""FuguaiFuguai"?"?
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BagaimanaBagaimana menemukanmenemukan ""FuguaiFuguai"?"?
Tahap 1 - Observasi
Sebelum melakukan apapun, pertama kali observasi mesin secara keseluruhan
untuk menemukan semua defect/cacat an terlihat
Tahap 2 - Pembersihan (fase pertama)Membersihkan mesin secara keseluruhan a ar semua defect an tersembun i
dapat ditemukan (tidak tertutupi)
-Pembongkaran bagian utama dari mesin, dan jika mungkin, temukan defect
yang terlihat seperti yang telah dilakukan pada tahap 1
Tahap 4 - Pembersihan (fase kedua)Membersihkan bagian2 dan komponen2 yang dapat diakses setelah
In Association withIn Association with
Tahap 5 - Perakitan44
MembersihkanMembersihkan dengandengan berpikirberpikir adalahadalah menemukanmenemukan fuguaifuguai
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MembersihkanMembersihkan dengandengan berpikirberpikir adalahadalah menemukanmenemukan fuguaifuguai
In Association withIn Association with
45
Step 1: List of HTA & SOCStep 1: List of HTA & SOC
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Step 1: List of HTA & SOCStep 1: List of HTA & SOC
Daftar Hard to Access Areas area sulit di an kau dan Source of
Contaminations (sumber kontaminasi) yang disiapkan oleh tim selama step 1
sebagai persiapan untuk step 2.
ber
si
aftarSum
o
ntamin
yg
au
D
ftarAre
a
litdijangk
DS
46
Contoh pembersihan awal & setelah
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Contoh pembersihan awal & setelah
menghilangkan abnormality
DG Area
Compressor Area
47
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Standar Antara
Pr epared : 16.11.2000
Revised :
Panther
L oca ti on : Pa cki ng Ha ll
Equipment : FlexLeader : Mr.Fulan bin Fulan
Tag No :
AUTONOMOUS MAINTENANCE STANDARD (Clean ing , Checking , and
Lubricating)Group :
Acti on if TimeInterval
Shift Daily Week ly Monthly Quar ter ly
Sealing SurfaceNo lamination,No
shampoo Clean 2 minutes D254,D246,D122
Batch cutter
blade
No Lamination,no
shampoo, Clean 2 minutes D69,D110,D304
ll i l i
espons y
HORIZONTAL SEALER
T P Man ar e o oo
Required (Min)
ll . , i . l i , ,
Sealing jawsNo laminate,No
smampoo, Clean 1 minutes D254,D246,D122
Flexible Hose No shampoo Clean 2 minutes D86,D302,D417
Motor No dust, Clean 2 minutes D69,D110,D306
VERTICAL SEALER
FILLING NOZZLES
Clutch break
assemblyNo dust,
Clean 2 minutes D86,D302,D417
Colleting drive No shampoo, Clean 3 Minutes D254,D246,D122
Dancing roller No Dust Clean 2 Minutes D86,D302,D417
MAIN DRIVE
Ins ide area No Dus t Clean
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Ste 02Ste 02
Ste 02Ste 02
Eliminasi area yg sulit dijangkauEliminasi area yg sulit dijangkauEliminasi area yg sulit dijangkauEliminasi area yg sulit dijangkau
sumber kontaminasisumber kontaminasisumber kontaminasisumber kontaminasi
49
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u uan
dan pengkerakan serta berusaha memperbaiki bagian-bagian ygsukar dibersihkan atau dilumasi sehingga pelaksanaan
pe er aan-pe er aan tu e mu a an cepat.
50
Step 2: Tindakan terhadap HTA
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p p
AFTERBEFORE Covers on the rare side of Plodder made transparent for Ease in
Inspection
AFTERBEFORE Covers on the side of Plodder Made Transparent for Ease in Inspection
51
Step 2: Tindakan terhadap HTA
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p p
AFTERBEFORECovers on the sides of Roll Mill made transparent for ease in inspection
AFTERBEFORE Roll Mill Motor relocated to the top to eliminate Hard to Access Area
52
Step 2: Tindakan terhadap HTA
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p p
AFTERBEFORE The cover on the Gearbox made transparent for immediate inspection
during running of machine.
AFTERBEFORE Hard to Access Area removed for adjustment on ACMA
53
Step 2: Tindakan terhadap SOC
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BEFORE AFTERFaulty Lip seals were a major source of contamination in the Sachet
Filling Assembly
BEFORE ACovers installed to guard against dust.
54
Step 2: Tindakan terhadap SOC
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BEFORE AFTERContamination of electrical septical due to improper posi tion of hopper
drain line.
Chute installed to revent em t cartons from fallin downBEFORE
55
Contoh -AM Step 2-
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Contoh AM Step 2
Tindakan terhadap sumber pengotoran
56
Contoh -AM Step 2-
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p
Tindakan terhadap sumber pengotoran
Before After
57
Contoh -AM Step 2-
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Tindakan terhadap sumber pengotoran
Before After
58
Contoh -AM Step 2-
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p
Tindakan terhadap sumber pengotoran
Modifikasi eralatan untuk mem ermudah
Before After
pembersihan dan pelumasan
59
Contoh -AM Step 2-
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Tindakan terhadap area yg sulit dijangkau
Modifikasi peralatan untuk mempermudah
pembersihan dan pelumasan
Before After
60
Contoh -AM Step 2-
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Install cover dan jendela transparan untuk
Tindakan terhadap area yg sulit dijangkau
Aftermembuat pengecekan lebih mudah
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CLI Standards
62
JISHU HOZENJISHU HOZEN -- StepStep--33
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tep : em uatan tan ar ntara
u uan:
.
Selain itu juga meningkatkan keandalan peralatan dengan
membuat serta melaksanakan standard sementara yg dapat
Standard meliputi Pembersihan (Cleaning), Pelumasan
(Lubricatin ), dan Pen encan an Baut-baut (Ti htenin )
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Masalah yang hanya
30%CLIT* tidakdilakukan
Kerusakan yg
tdk dipantau
yg uru
Tidak mengikuti
prosedur operasi
SOP
Masalah yang dapat
engineering (produksi dan
maintenance)
70% cega engan
* = , , ,
Tightening (Pengencangan)
In Association withIn Association with
64
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65
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Area: H&B: TSO: Bejo Compiled By: Date:Line # 5 Line Leader 1
stDraft P. Schier 15/12/97
Machine Filler /Capper 2nd
Draft
Ref Drawing: Revision 2: M. Bite 19/01/00
No Location Standard M/C
Status
Inspection Action Time
Mins
Intervals Person in
Charge
Method Tool(s) D W F M
1. Filler vacuum
pot.
Cleaned free of
liquid
Stopped Visual Remove pot &
rinse with hot
water
Hot water 2min
Operator
C
L
E
2. Capper
vacuum pot
Cleaned free of
plastic debris .
Stopped Visual Remove pot &
rinse with hot
water
Hot water 2min
Operator
A
N
I
3. Filler bed Cleaned free from
liquid or spills
Stopped Visual /
touch
Wipe clean with
alcohol and
paper towel
Alcohol and
paper towel
5min
Operator
N
G
4. Filler doors Cleaned free from
liquid and dust
Stopped Visual Wipe down with
Jif glass and
paper towel
Jif glass and
paper towel
5min
Operator
5. Keystation Clean free of
product
Running Visual
/touch
Wipe down with
alcohol and
paper towel
Alcohol and
paper towel
2min
Operator
6. Plate & plate
covers
Cleaned free of
product
Stopped Visual
/touch
Wipe down with
alcohol and
paper towel
Alcohol and
paper towel
5min
Operator
7. Cap Plate Clean free of liquid Stopped Visual Wipe down with
alcohol and
paper towel
Alcohol and
paper towel
1min
Operator
66
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Area: H & B: TSO : Pat Colem an Com piled By: Date:Line # 5 Line Leader 1 stD raft P. Schier 15/12/97
M achine Filler /Capper 2nd Draft
Ref Draw ing: Revision 2: M . B ite 19/01/00
No Location Standard M/C
Status
Inspection Action Time
Mins
Intervals Person in
Charge
Method Tool(s) D W F M
1. Capping plate
leads
Check for damage Stopped Visual /
touch
None 1min
Operator
N
. ompresse
air valve
ec n green
zone
unn ng sua one m n
pera or
S
P
3. Oil gauge
vacuum pump
Check if in zone Running Visual None 1min
Operator
E
C
4. Guarding bolt
around filler
Check no screws or
bolts missing
Running Visual Try turning
screws by hand
None 1min
Operator
I
O
. a es p a e
cover
ec or
burrs,chips or
plastic shavings
oppe sua
touch
one m n
pera or
N 6. Gearbox oil
gauge (rear of
filler)
Check oil level is
between markings
Running Visual None 1min
Operator
.
air pot
filled to marking
and is not damaged
touch
leaking
8. Capping head Check the end of
nozzle for burrs
Stopped Visual /
touch
None 1min
Operator
9. Capping plate Check leads are not Stopped Visual / None 1min
Operator
10. Filler guide
rails
Check are not
damaged
Stopped Visual None 2min
Operator
67
CLI records attached to equipmentCLI records attached to equipment
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68
Cleaning & Inspection CalendarCleaning & Inspection Calendar
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69
CLI standards and records at the lineCLI standards and records at the line
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Operator lubricating machine
,
70
STEP 3 (TENTATIVE STANDARDS)STEP 3 (TENTATIVE STANDARDS)
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71
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74
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75
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76
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77
AM Step 1-3
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- Kondisi Dasar Mesin yang baik bisa dicapai dengan melakukancleaning (5S) dan inspeksi
- Adanya sistem utk mempertahankan kondisi yang sudah dicapai
- Hasil Nyata yang bisa dilihat dari TPM
AM S1 AM S2 AM S3
Pembersihan Awal Sumber pengotoran Standar Antara
& daerah yg sulitdibersihkan
CleaningDaftar Abnormality
Check list & Standar:- Pelumasan
TaggingMinutes Meeting
FIOPL
- Kebersihan
- Pengencangan baut
78