1

TPM for lean manufacturingChap４．Step of “Jishu-Hozen “Activities

Quote From ：TPM Deployment program

TPM encyclopedia Keyword Book

（Japan Institute of Plant Maintenance)

Created by Japanese Gemba Kaizen Web

2

４．Step of “Jishu-Hozen “Activities

4.1 ・・・ What is Jlshu-Hozen ？ ・・・・・P62

4.2 ・・・Conservation activities of manufacturing departments ・・・・・P65

4.3 ･･･Conservation activities of maintenance department ・・・・・P66

4.4・・・Step method for the development of “Jishu-Hozen” ・・・・・P67

4.5・・・ Step1： Initial-phase cleaning ・・・・・P69

4.6・・・・Step2：Countermeasures for the source of problems ・・・・P71

4.7・・・Step3： Establishment of tentative standards for“Jishu-Hozen”・P72

4.8・・・ Step4：General [overall] inspection ・・・・・P73

4.9 ・・・ Step5： Autonomous inspection ・・・・・P74

4.10 ・・・ Step6：Standardization ・・・・・P75

4.1１ ・・・ Step 7:Thorough implementation of autonomous ・・・・・P79

3

４．１ What is Jishu-Hozen ？

• Keep their equipment by yourself！

・Become operator who can understand

equpment !

Break away from “I am operator and

You are maintenance man”

Jishu-Hozen”

1. Significance of “Jishu-Hozen"

“Jishu-Hozen“ means activities of the

operator that uses maintenance to personally

conduct maintenance activities, including

cleaning, oiling,retightening, and inspection,

thereby raising production efficiency to its

limit. Such activities will prevent forced

deterioration of equipment.

Thus,“Jishu-Hozen” represents activities to

thoroughly eliminate failures, minor

stoppages, defects, and other losses to

restore equipment to their desirable forms,

maintain them, and improve them, and at the

same time to develop “personnel that are

skillful at equipment operations and

improvement.“

“Jishu-Hozen” is the operators work itself. it

is carried out under the step method through

small group activities closely unified with the

managerial structure. it represents a major

characteristic of TPM

PM is designed to pursue production system

efficiency to its limit through “corporate

structural improvement based on the

constitutional

improvement of personnel and facilities," and

"Jishu-Hozen“ itself signifies the onstitutional

improvement of personnel and facilities. This

entails the changing of workers’ ways of

thinking and behaviors,

To attain this, first replace the concept of the

division of labor between operation and

maintenance, represented by the view that “l

am an operator, and you,maintenance man,

fix "it" with the thinking of “protecting one‘s

equipment by oneself.“

4

To translate this thought into action, the

development of personnel that are skillful at

equipment operations and improvement is

pushed for, to foster personnel who are

versed in the structure and function of

facilities; who have acquired maintenance

skill to apply improvement.

For the structural reform of personnel, it is

highly effective to bring about the structural

improvement of equipment currently being

used. in “Jishu-Hozen“, as the first step to

“protect one’s equipment by oneself," work

should be started with improvement of basic

conditions of the equipment being used

(cleaning, oiling, and retightening). Then,

based on the step

method, structural improvement of quipment

should be effected so that

the equipment will be the form as it should

be. As a result, overall equipment efficiency

will improve greatly, and the operator

personally experiences the effect of “Jishu-

Hozen", so that his “structure” will be

changed so as to protect his own equipment

by himself. Thus, in “Jishu-Hozen", the

constitutional improvement of personnel and

equipment proceed simultaneously.

Also, “Jishu-Hozen" is a self-management

activity by small work-site

groups. Keys to the activation of small

groups are said to be “morale,

skills, and places for actions.” The

prerequisite is creation of the “places for

actions,“ and introducing only “Jishu-Hozen"

would prove ineffective.

it should be promoted as one of the five

pillars (or eight pillars) of TPM development

of the entire company/establishment.

5

6

４．２ Conservation activities of

manufacturing departments

1. Activities to prevent degradation ① Correct operation

② Cleaning, Refueling, Retightening

③ Adjust

④ prediction of abnormal

⑤ Recording Data of conservation

２．Activities to measure the degradation(By five senses)

①Daily check

②Periodic check

３．Activities to recover the degradation

①Easy replacement of parts, emergency response in the event of failure

②Quick communication for failure

Important is prevent degradation

7

４．３ Conservation activities

of maintenance departmentHigh Conservation activities

①Focused on the areas that require high technology

Periodic maintenance, predictive maintenance, corrective maintenance

２．Support for Conservation activities of manufacturing section

① Education equipment function

② education bolts and nuts

③ Education of lubricating oil

④ skills education inspection

⑤ One Point Lesson

Important is measure and Restoration of

Degradation

４．４ Step method for the development

of “Jishu-Hozen”

1st step: lnitial cleaning (cleaning/inspection)

While thoroughly eliminating dust, dirt, etc,

from inside the cover and cleaning every

corner of the equipment, detect and correct

equipment nonconformity/latent defects for

restoration, oil, and retighten, through

cleaning, and thereby prevent forced

deterioration.

2nd step: Countermeasures for contamination

sources and hard-to-access areas

Detect sources of dust and stains, prevent

scattering of dust, and improve hard-to-access

areas for cleaning, oiling, retightening, or

inspection, and shorten time for these

activities.

3rd step: Preparation of the tentative

standards for “Jishu-Hozen"

Prepare action standards to be observed by

oneself, so that cleaning,oiling, retightening,

and inspection can be surely performed in a

short period of time.

4th step: general inspection

To improve equipment efficiency to the limit,

understand the structure, functions, and

principles, and how the equipment should

be; inspect the main mechanism and parts

that constitute the equipment with the eyes of

an “operator skillful at equipment operations

and improvement" without exception; detect

latent

defects; and restore or improve the equipment

to desired conditions.

8

5th step: Autonomous inspection

Review the tentative autonomous standards

and general inspection standards, prepare

“Jishu-Hozen” standards that provide for the

efficient of inspection and prevention of

inspection errors, and maintain the equipment

in its desirable conditions.

6th step: Standardization

The items to be controlled at work sites

include raw materials/products, dies/jigs/tools,

measuring instruments,cleaning/inspection

outfit, and transport equipment, in addition to

facilities. They also include written work

standards and records.

Review and standardize them, and strive for

zero losses.

7th step: Through implementation of self-

management

With self-confidence, based on past results

obtained by changing

9

lnitial cleaning, Countermeasures for contamination sources,

Preparation of the tentative standards for “Jishu-Hozen“,

general inspection, Autonomous inspection, Standardization,

Through implementation of self-management

10

４．５ Step １：Initial-phase cleaning

Cleaning is inspection

The 1st-step activity of “Jishu-Hozen". It

aims to totally eliminate accumulated dust

and stains by thoroughly cleaning all parts of

equipment;

to find latent detects of the equipment, such

as contamination sources,hard-to-clean

areas, and nonconformities that may cause

failures/detects or accidents through

cleaning activities; and to take corrective

steps about the problems which they think

they can fix. Discovered nonconformities and

their contamination sources are highlighted

by attaching ‘efu' (tags) to them.

Cleaned portions naturally get dirty again as

a result of production activities, and it is also

an important activity to measure the time

until they

become dirty and how dirty they are, and to

study steps to prevent the occurrence at

stains.

11

４．６ Efu / TagA tag, equivalent in size to the one affixed to

baggage, is attached to nonconformity

detected for marking. These tags are

classified into white efu and red efu. White

efu is attached to the location at

nonconformity that can be rectified by

operators in “Jishu-Hozen“, while red efu is

attached

when maintenance workers must be called

in for fixing. On the front at efu,

the date of nonconformity detection, the

finder, and the content of nonconformity

should be entered, with an illustration of the

nonconformity added.

On the back of the tag, the content of the

required improvement should be entered.

After an improvement step is completed, the

tag should be withdrawn, and the results of

the step should be additionally recorded.

Unremoved etu indicates that no corrective

measures have been taken as yet, so the

tags

serve the purposes of reminding people of

remaining number of nonconformities to be

addressed.

12

4.7 Step2：Countermeasures for the source

of problemsActivities in the 2nd step of “Jishu-Hozen".

They consist at work to improve sources of

dust and stain detected in the 1st step; to

prevent dust,

stain and dispersion and clean the places;

and to improve locations where oiling is

difficult, so as to reduce time for cleaning or

oiling and enhance

equipment maintainability‘ Where cleaning

is difficult, improvement may be made at

cleaning tools and/or methods at cleaning.

Also,lone can measure the cleaning time

required to realize the state of cleanliness

where a malfunction can be detected while

operating the equipment, so as to reduce

such a cleaning time.

The target “maintenance cleaning time"

should be five minutes per day, per

operator and two hours per month, per

operator; one should repeat improvements

until these targets are attained,This is a

step where brain rather than money should

play a role.

4.8 Step３： Establishment of tentative standards

for “Jishu-Hozen”

Establishment of tentative standards for

“Jishu-I-lozen”

The 3rd-step activities of “Jishu-Hozen".

Members should work out provisional

cleaning standards to maintain the 1st-step

level for approved

cleaning and the 2nd-step level for machine

conditions that have dealt with contamination

sources/hard-to-access areas; to clean and

inspect daily or regularly; to repeat

improvement; and to ensure prevention at

equipment

degradation. it is also necessary to review oil

supply and lubrication conditions, to detect

and rectify nonconformities and hard-to-oil

and-inspect spots, and to prepare provisional

oiling standards, thereby seeking the

improvement of equipment reliability and

maintainability and completing standards that

can be easily kept

13

Activities to be implemented as the 4th step

in “Jishu-Hozen", designed to “foster

operators really skillful in equipment

operations improvement."

Operators should study and understand the

structure, functions, and principles of

equipment, as well as its desirable

conditions; inspect

principal mechanisms/parts that compose

the equipment, thoroughly and without

omission, from the eyes of skillful operators;

reveal potential

defects; and restore original conditions.

The operators should be trained regarding

such items as machine elements,

lubrication, pneumatic pressure, hydraulic

pressure, electricity, driving mechanism,

equipment

safety, and processing conditions; they

should conduct inspection regarding these

items, and learn skills to find nonconformity.

Also, while

inspection standards are prepared to ensure

conformance, equipment should be

improved for easier inspection, and ideas for

visual control

should be embodied.

14

4.9 Step4：General [overall] inspection

Education

5.0 Step5： Autonomous inspectionActivities to be conducted as the 5th step for

“Jishu-Hozen“. Based on the experience in the

1st to 4th steps, circle members should review

the

present written standards on cleaning, oiling,

and general inspection from

the viewpoints of:

[1] zero failures/detects,

[2] inspection efficiency improvement,

[3] inspection work load balance, and

[4] visual control.

Operators should also clarity the work-task

sharing with the maintenance

department for each equipment, upgrade the

standards with inspection efficiency

improvement and error-free inspection to be

completed as

autonomous inspection standards.

Also, they should further study equipment

operation and relations between quality and

equipment, thereby developing capability oi

right operation and early detection of

abnormalities.

15

16

4.10 Step６：Standardization

(“Jishu-Hozen”)The 6th step of “Jishu-Hozen”. While steps to

5 involve activities that focus on

improvement and inspection of basic

equipment conditions, the6th step aims at

ensuring that these steps are taken as a

matter of course for control purposes, that

the role of operators will be extended over

and beyond equipment operation to

include that of reducing losses

aggressively and that "jishu-Hozen" will

take place to the fullest extent.

Specifically, this step involves overall review

and systematization at various

maintenance and control device such as

physical distribution standards, data

records, standards die/jigs/fixtures,

standards and the like

17

4.11 Step 7:Thorough implementation

of autonomous

Activities at the final seven-step stage at

“Jishu-Hozen". Here, all the activities

performed this far are boiled down,

and improvement is repeated

through small group autonomous

management activities.

Although the word "autonomous" is used,

the small-group activities are basically

tied to the

company policy and targets, so that

whatever these small groups may

establish as circle targets, whatever

they may take up as improvement

themes,

and whatever autonomous activities they

may continue to attain more efficient

production — in other words, all such

activities operational for upkeep and/or

improvement — should become part of

the company operations.

18

Thank you for watching the show.

Please read the next chapter at My Home Page

and I hope Like us on Facebook

Regards.

Here my personal site→Japanese Geｍba Kaizen Web

my firm site →crane techno consultantｉｎｇ