Jishu Hozen

TPM Club India Autonomous Maintenance Pillar
PILLAR
Jishu Hozen
or
Autonomous Maintenance
1
Reasons Why Autonomous Maintenance is Required

No satisfactory increase in the
performance record can be seen … Activities to keep
record on equipment
• Confirmation of degradation
working conditions
• Daily inspection
• Periodical inspection
Activities to prevent
equipment
degradation
• Keep cleaning
• Inspection
• Additional
tightening
Activities to
Preventive Production restore the
Maintenance Maintenance TPM machine
conditions
Japanese
U.S style of PM
style of PM
Maintenance
Department’s
sole • Frequent servicing
responsibility
• Solution of abnormality
• Good communication
2
Classification of Maintenance and Responsibility

Implementation Assigned
Classification Operati Maintena
Prevention Measurement Restoration
on nce
Proper Operation
Normal Operation
Set-up and adjustment
Cleaning, Address Latent Defects
Preventive
Lubrication
Maintenance
Daily Maintenance Retightening
Operation Condition, Daily Inspection for
Deterioration
Minor Check
Time – based Inspection
Time based
Time – based Inspection
Maintenance
Time – based Check
Productive
Maintenance Tend Check
Predictive
Maintenance Unscheduled Check
Strength KAIZEN
Corrective Maintenance Lightening of Loading
(Reliability)
Accuracy Improvement
Corrective
Maintenance Corrective Conditions Monitoring
Maintenance
KAIZEN of Check Operation
(Maintain-ability)
KAIZEN Of Check Operation
Check Quality KAIZEN

Others
Maintenance MP Activities
Prevention
Planned Breakdown Maintenance
Breakdown
Maintenance Earlier discovery of interior situation and positive
Emergency Maintenance
and rapid report/remedy
Sporadic Repair
3
Autonomous Maintenance
•Inspect & lubricate daily I take care of

my own machine
•Replace parts and make repairs
•Detect abnormalities early
•Check precision
4
Relationship Between Forced Deterioration and Losses

Example of Forced Deterioration
Due to Inadequate Cleaning
1. Cause of failure Contamination by dirt or fallen matter in rotating
parts, sliding parts, air and oil pressure systems,
electrical control systems, sensors, etc. causes a
drop in accuracy, misoperation or a failure due to
wear, jamming, resistance, poor electrical
conductivity, etc.
2. Cause of quality Direct contamination by foreign matter in products
and misoperation of equipment results in quality
defects.
3. Cause of forced Waste and dirt makes it difficult to inspect for
deterioration looseness, cracks, play and out-of-oil conditions,
resulting in forced deterioration.
4. Cause of speed Dirt increases frictional resistance and sliding
losses resistance resulting in speed losses such as
decreased performance and idling.
5
Examples of Steps for Evolving Autonomous

Maintenance
Step Name
1 Initial clean-up All-around clean-up of dust and dirt, centering on equipment proper,
and implementation of lubrication, and machine parts adjustment;
discovery and repair of malfunctions in equipment
2 Measures against Sources Prevent causes of dust and dirt and scattering, improve places which are
difficult to clean and lubricate and reduce the time required for clean-up
and lubrication.
3 Formulation of clean-up and lubrication Formulate behavioral standards so that it is possible to steadily sustain
standards clean-up, lubrication and machine parts adjustment in a short period
(Necessary to indicate a time frame-work that can be used daily or
periodically)….
4 Overall inspection Training in check-up skills through check-up manuals; exposure and
restoration of minor equipment defects through overall check-ups
5 Autonomous check-up Formulation and implementation of autonomous check-up sheets

6 Orderliness and tidiness Standardize various types of on-the job management items and devise
complete systematization of up-keep management.
• Standards for clean-up, check-ups and lubrication
• Standards for physical distribution in the workplace
• Standardization of data records
• Standardization of die management, jigs and tools
7 All-out autonomous management Development of corporate policies and goals, and making improvement
activities routine : Steadily record MTBF analysis, analyze these, and
carry out equipment improvements
6
Four Steps to Become An Operator Strong on

Equipment And Autonomous Maintenance
Autonomous Four steps to

Maintenance become an
7 steps operator strong on
equipment
7 All-out autonomous management 4 Master how to repair the equipment
6 Orderliness and tidiness Learn how to operate the equipment

3 with the required accuracy and how to
evaluate the product quality
5 Autonomous check-up
4 General inspection
2 Study the mechanism and functions of
3 Formulation of clean-up and lubrication equipment and machines
standards
2 Measures against sources of outbreaks Familiarize with the concept of equipment
1 maintenance and improvement and with how
1 Initial clean-up to put the idea into practical realization
7
How to Concretely Develop “Jishu-Hozen”

The outline is mentioned in the 1st through 3rd stages, but how to
concretely develop the activities is as per Table IV-2.
Table IV -2
Development of “Jishu-Hozen” (For equipment)
Step Category Activities Target Guidance and
Equipment Operator promotion
• Complete elimination of dust and • Prevention of forced • Formation of mind • Pointing out and
dirt, especially on equipment deterioration caused by attachment to the guidance of the priority
* Establish of basic conditions (cleaning, lubrication and retightening)
* Trained operators to be proficient in equipment and reduction in failure rate

• Performance of lubrication and dust or dirt equipment through clean-up areas.
retightening, and discovery and • Discovery and touching and handling • Instruction in the
rectification of slight equipment rectification of latent the equipment importance of clean-up
Initial clean- defects defects thorugh clean-up • Cultivation of the (education)
1st up ability to identify
(Cleaning • Removal of unnecessary things, • Discovery of areas where
equipment “fuguai”
• Preparation of
and orderliness and tidiness of tools and clean-up and inspection diagnosis sheets
inspection jigs are difficult • Recognition of the • Responsibilities in the
• Removal of unnecessary importance of clean- operation and
things around equipment up implementation of
• Rationalization of activities
lubrication
Counter- • Implementation of countermeasures • Making the equipment • KAIZEN of nearby • Concept and practice of
measures for against such sources as dust and dirt, cleaning and inspection items to practice and equipment KAIZEN
the causes and prevention of splashing of leaks easy through improvement to master the • How to prepare the
of forced • Implementation of countermeasures of the sources of dust and application of the criteria or standards
deterioration against the areas where cleaning and dirt, and areas where KAIZEN method and • Implementation of
2nd and inspection are difficult (Operation inspection and cleaning concept visual control and
improviding improvement for shortening the time are difficult • Enjoy the KAIZEN instruction on device
hard-to needed for cleaning and service) • Improvement of activities (Pleasure of development
access areas • Ranking the priority places for daily maintainability hand-made)
inspection
• Confirmed of KAIZEN and its effect
© JIPM, 1987
8
How to Concretely Develop “Jishu-Hozen” (Contd.)

• Preparation of action criteria to • Keeping the 3 basic • Self-decision of criteria • Preparation of
allow positive clean-up, lubrication elements of equipment and its strict observance standards for
Preparation and retightening maintenance within maintenance clean-up, • Each worker learns to be technologies and
of tentative shortest time lubrication and aware of individual techniques
3rd relighting
“Jishu- • KAIZEN of inspection method and roles. • Clarification of
Hozen” visual control procedures to study
standards what the equipment
must be
• Mastering inspection skill, utilizing • Restoration of • Acquaintance of • Preparation of
inspection manuals deterioration by inspection skill training text for
• Discovery and restoration of general exterior general • Understanding the general inspection
* Through implementation and maintenance of inspection

inspection inspection of equipment functions and • Planning of education
• Preparation of autonomous equipment and mechanism and training schedule
inspection standards reliability • Mastering how to put • Execution of leader
General improvement. together data and how to training
4th inspection • KAIZEN of areas use it • Follow-up of
where remedial action • Activation through education and
and normal inspection KAIZEN activities training
are difficult
• Learning the importance • Preparation of
• Making inspection of education on general inspection
efficient communication manual and check
sheets
• Review clean-up, lubrication and • Positively keeping the • Maintenance of one’s • Teaching how to
Autonomou general inspection criteria and restoration from own equipment by precisely analyze the
s inspection integrate them into comprehensive deterioration by means oneself data
criteria to contribute to efficiency of general inspection • Self-decision and strict • Effective equipment
activities • KAIZEN of equipment observance management and
5th • Preparation and implementation of which has good • “Jishu-Hozen” is maintenance
autonomous inspection check sheets operability learning what the ideal
• Improvement of visual control and
operability
© JIPM, 1987
9
How to Concretely Develop “Jishu-Hozen” (Contd.)

• Picking the items to be • KAIZEN of • Improvement of • Technical guidance to
* KAIZEN activities, including those for problems related to equipment

managed equipment reliability,
management technology promote
maintainability and standardization
* Making the strong structure which can perform “Jishu-Hozen management

• Standardization of • Expansion of “Jishu-
6th operability
management items and Hozen” management • Revision of
Standardization
systematization of • Review and KAIZEN scope management
maintenance management of equipment standards and
• Thoroughness of visual
environment and thoroughness of
control
layout management
• Development of company • Kaizen of equipment • Enhancement of goal • Technical assistance

policy/goals and quantitative reliability consciousness and for equipment
analysis of KAIZEN maintainability and thorough cost KAIZEN
activities operability through consciousness, including
• Standardization of
equipment KAIZEN maintenance cost
• Positive implementation of improved items
by applying various
Autonomous MTBF analysis and • Acquirement of skill to
data analysis • Education and
management recording perform minor repair by
training in repair
• Keeping overall oneself
(Recording failure by visual skills
equipment efficiency
7th control) and equipment • Acquisition of data
at its best
KAIZEN recording and analyzing
technique and KAIZEN
technology
© JIPM, 1987
10
Step 1 - Initial Cleaning
KEY POINTS
• Cleaning with Meaning
• Cleaning for no cleaning
• Inspection means finding problems
• Identification of abnormalities
11
Any thing
We’ll clean wrong here
every nook
and corner
Anything we
can fix right
away, we will
Cleaning is inspection
12
Step 1 - Initial Cleaning : Activities

 Thorough cleaning of machines and identify
fuguai. White tag Red tag
 Attaching tags for fuguais depending upon the
nature.
 White tags for fuguais to be attended by the
operatives.
 Red tags for fuguais to be attended by the
specialists ( Maintenance personnel or sub-
contractor)
 Green tags for fuguais found in the similar type
of machines also to be considered for JH Green tag
machines.
 Fuguais will be linked to conditions which may
lead to breakdown, defect and unsafe
conditions.
 Do audit and get passed.
 Go for step 2.
13
Table 4-6. Sample Manual on Exposing Seven Types of Abnormality
Abnormality Examples
1. Minor flaws Dust, dirt, powder, oil, grease, rust, paint
• Contamination
• Damage Cracking, crushing, deformation, chipping, bending
• Play Shaking, falling out, titling, eccentricity , wear, distortion, corrosion
• Slackness Belts, chains
• Abnormal phenomena Unusual noise, overheating, vibration, strange smells, discoloration, incorrect pressure or current
• Adhesion Blocking, hardening, accumulation of debris, peeling, malfunction
2. Unfulfilled Basic Conditions

• Lubrication Insufficient, dirty, unidentified, unsuitable or leaking lubricant
• Lubricant supply Dirty, damaged, or deformed lubricant inlets, faulty lubricant pipes
• Oil level gauges Dirty, damaged, leaking ; no indication of correct level
• Tightening Nuts and bolts : slackness, missing, cross-threaded, too long, crushed, corroded washer unsuitable,
wing nuts on backward
3. Inaccessible Places
• Cleaning Machine construction, covers, layout, footholds, space
• Checking Covers, construction, layout, instrument position and orientation, operating – range display
• Lubricating Position of lubricant inlet, construction, height, footholds, lubricant outlet, space
• Tightening Covers, construction, layout, size, footholds, space
• Operation Machine layout : position of valves, switches, and levers : footholds
• Adjustment Position of pressure gauges, thermometers, flow meters, moisture gauges, vacuum gauges, etc.
Contamination Sources
4.
• Product Leaks, spills, spurts, scatter, overflow
• Raw Materials Leaks, spills, spurts, scatter, overflow
• Lubricants Leaking, split, and seeping lubricating oils, hydraulic fluids, fuel oil,etc.
• Gases Leaking compressed air, gases, steam, vapors, exhaust fumes etc.
• Liquids Leaking split and spurting cold water, hot water, half-finished products, cooling water, waste water
etc.
• Scrap Flashes, cuttings, packaging materials, and nonconforming product
• Other Contaminants brought in by people, fork-lift trucks, etc. and infiltrating through cracks in buildings
14
Table 4-6. Sample Manual on Exposing Seven Types of Abnormality : Contd...
Abnormality Examples
5. Quality Defect Sources

• Foreign matter Inclusion, infiltration and entrainment of rust, chips, wire scraps, insects etc.
• Shock Dropping, jolting, collision, vibration
• Moisture Too much, too little, infiltration, defective elimination
• Gain size Abnormalities in screens, centrifugal separators, compressed – air separators etc.
Inadequate warming, heating, compounding, mixing, evaporation, stirring, etc.
• Concentration Inadequate warming, heating, compounding, mixing, evaporation, stirring etc.
• Viscosity
Unnecessary and Non-

6. urgent items
• Machinery Pumps, fans, compressors, columns, tanks, etc.
• Piping equipment Pipes, hoses, ducts, valves, dampers, etc.
• Measuring instruments Temperatures, pressure gauges, vacuum gauges, ammeters, etc.
• Electrical equipment Wiring, piping, power leads, switches, plugs etc.
• Jigs and tools General tools, cutting tools, jigs, molds, dies, frames, etc.
• Spare parts Standby equipment, spares, permanent stocks, auxiliary materials, etc.
• Makeshift repairs Tape, string, wire, metal plates, etc.
Unsafe Places
7. • Floors Unevenness, ramps, projections, cracking, peeling, wear (steel deckplates)
• Steps Too steep, irregular, peeling anti-slip covering, corrosion, missing handrails
• Lights Dim, out of position, dirty or broken covers, not properly explosion-proofed
• Rotating machinery Displaced, fallen off or broken covers, no safety or emergency stop devices
• Lifting gear Wires, hooks, brakes, and other parts of cranes and hoists
• Other Special substances, solvents, toxic gases, insulating materials, danger signs, protective
clothing etc.
15
Identification of forced deterioration
16
17
18
19
20
21
22
EXAMPLE OF ABNORMALITY
( LOOSE FITTINGS )
23
EXAMPLE OF ABNORMALITY
( LEAKAGES )
24
ABNORMALITY TAGS
White Tags Removed by Line Operators Red Tags Removed by Skilled Person
25
TPM Club India
Worn-out Autonomous Maintenance Pillar
26
ELIMINATION OF FORCED
DETERIORATION
Before After
27
ELIMINATION OF FORCED
DETERIORATION
Before After
28
Step 2 - Measures against

Sources
KEY POINTS
• Stop contamination at source
• Minimise (localise) contamination
• Easy to Clean, Lubricate, Retighten &
Lubricate
• Uncover to discover
• Take counter measure against Forced
deterioration
29
EASY TO CLEAN
Means easy to clean,

collect, dispose & inspect
Use of localised guards
30
Step 2 : Countermeasure for the causes of Forced Deterioration and Improving and Hard-to Access Areas
Purposes :
• Eliminate sources generating dirt, dust and stains, prevent splashing and flying and improve places
that are hard to access, oil and check to shorten the time needed for cleaning, oiling and inspection
• Learn approach to equipment KAIZEN and achieve tangible results
© Understand evils of dirt, © Find places with dirt, stains, dust and foreign © What are hard-to-access areas
stains, dust and foreign matter matter accumulated • Time-consuming places
© Analyze dirt, stains, dust and foreign matter • Places difficult to do
 material, shape and composition
© What type of work is performed?
• Cleaning, oiling, inspection
Gather quan-tified data © Analysis of generating sources • Which tools are used ?
• Do they generate in a prior processes ? • Can work be performed in a visible
© Why do they generate ? • Do they generate in one’s own process ? state ?
• Are they generated by machining ?
• How are results checked?
• Are they generated by equipment ?
• Do they come form the outside the plant ?
• Visual examination hand….
© Learn how to think of © Devise countermeasures © Devise countermeasures Present daily cleaning
KAIZEN • Eliminate generating sources • Goal time and inspection goal
• Prevent splashing and flying • Improvement method time
• Prevent instrusion and attaching
• Schedule, operators in charge, plan
• Eliminate
• Focus Restoration and KAIZEN KAIZEN records

•Prevent Check results of KAIZEN measures Reexamine tentative standard prepared in
splashing and step 1 and tentative standard improved
Reexamine tentative cleaning standard
flying afterward
Matters pointed
Clean in accordance with tentative cleaning standard
out Check if cleaning can be finished accurately
within time specified in tentative standard and
Autonomous audit remove “EFU”
Plant audit Circle activity report, application for
plant audit
Activities board
•………
Passed •………
© JIPM, 1987 •………
31
32
Minimise Contamination
33
Modify equipment to make cleaning easier
34
Install covers and inspection windows to

make checking easier
35
SOURCE OF CONTAMINATIONS
36
IDEA FOR ELIMINATING

FORCED DETERIORATION
37
THEME: LOSS NO
LOSS STRUCTURE:
KAIZEN MACHINE:
TEAM:
13B5SL
KAIZEN START
To reduce Cleaning time 8A
Cleaning Time Reduction S.Ravindharan 15.03.2001
V.Mohan
BENCH MARK 30 Sec IDEA: P.Comarasen KAIZEN FINISH
To provide a polythene paper on the K.Patchaiappan
TARGET 5 Sec magnet to collect contaminated material 16.03.2001
PROBLEM: COUNTERMEASURE: BENEFITS :

Before After
Contaminated Contaminated
Oi material Oi
lC lC material
hu hu
te te
Cleaning the contaminated • Time saving / month = 533 min
material deposited in the magnet Polythene
takes more time Magnet
Paper Magnet • Timings saving / Year = 6396 min
• Effortless activity
Oil tank Oil tank
Remove magnet & No cleaning remove

cleaning by brush with Polythene paper and fix
new polythene paper
diesel then fix magnet
ANALYSIS: RESULT: HORIZONTAL DEPLOYMENT :

WHY 1 WHY 2 WHY 3 Before After
Sec
Cleaning Iron Due to Area Status
30 30 Sec
the particles magnetic
magnet not property Socket 13
takes coming BETTER 15
Hex
more out 15
time easily Special 13
from 5 Sec
magnet
0
38
THEME: LOSS NO.

KAIZEN MACHINE:
CGR17H
KAIZEN START
LOSS STRUCTURE: TEAM: J. Srinivasan
To Reduce Cleaning Time inside the 8A
machine area in rolling machine
Cleaning Time Reduction
S.Jayaraman 03-06-2001
3 min / shift Krishnamoorthy KAIZEN FINISH

BENCH MARK IDEA:
To provide gaurds in the product discharge chute & D.Sivakumar 21-06-2001
TARGET “Zero” providing conveyor G. Devanathan
Before After Gaurd
Time saving = 3 Min / Shift
Man hours saved per year = 15 hours

Time taken for cleaning inside the
machine area is more Other Benefits
No Spill Over of Products

Tray No oil leakage
Oil S-Conveyor
Product
Oil Pit
spillover
ANALYSIS: Problem : Cleaning time is more RESULT: HORIZONTAL DEPLOYMENT :
WHY 1 WHY 2 WHY 3
mts
Basic design 3 min / shift

Products get 3
Cleaning time
spilled over
of chute Better No of rolling machines Target Date
is more in
inside the inside the
Identified : 9 Nos.
machine area machine area
in rolling and oil leakage Implemented : 6 Nos. 25-09-2001
machine from chute
Zero
0
Before After
39
EXAMPLES OF LOCALISED CONTAINMENT
Before After
40
Usage of
localised guards
41
Eliminate cleaning by fabricating chute for collecting

disposable waste.
After
Before
42
43
44
45
Actions to eliminate dust falling on the floor
46
Easy to lubricate
47
Countermeasures against source of contamination

Oil Localisation
Before After
Localised gaurds
The return oil flow from the feed drive gears splash and spread all around the
open space inside the machine there by getting contaminated. To avoid the
contamination, the return oil flow is channalised from the feed drive gears
directly to the lubrication tank
48
Easy to Lubricate
Before Machine cover After Machine cover
Grease points
Pulley Pulley Grease points
In TM19B tapping machine the plummer block The grease points have been brought
bearings (2 nos in every spindle and there are 4 out by means of tubes and greasing is
spindles) are lubricated once a week. This activity done even when the machine is
takes 20 minutes since the lub points are inside and running. In addition to avoidence of
machine covers to be removed and again loss of time,. It is also safe to carry out
assembled. It is also difficult to do this activity as the this activity like this.
grease points are in “Hard to access” areas.
49
DIFFICULT TO LUBRICATE
- EASY TO LUBRICATE
Before After
Difficult to Lubricate the oil to Easy to Lubricate the oil to

gear box gear box
50
Easy to Retighten
51
52
Easy to Inspect
53
THEME: LOSS NO.

KAIZEN MACHINE: 10B3S
KAIZEN START
LOSS STRUCTURE: TEAM: J. Sriram
To reduce Inspection time
8A Inspection Time Reduction
Karunairaja 10.05.2001
Franklin KAIZEN FINISH

BENCH MARK 30 sec / Day IDEA:
To bring the pressure gauge for K.O. system outside the Sivakumar 25.05.2001
TARGET 2 sec / Day machine for easy inspection
Ramalingam
Before After
Time saving = 28 sec / Day
Man hours saved per year = 15 hours

Inspection is very difficult and
taking more time in the pressure Pressure Other Benefits
gauge for K.O. system Pressure
gauge Inspection becomes easy
gauge
Inside the M/c
Outside the M/c
Difficult to Easy to
Inspect Inspect
ANALYSIS: Problem : Inspection is difficult RESULT: HORIZONTAL DEPLOYMENT :

WHY 1 WHY 2 WHY 3
Sec.
By machine 30 sec / change

Pressure gauge 30
Inspection is Better
kept inside the design
very difficult No of Areas
and it is machine
taking 15 Identified : 5 Nos.

moretime in
pressure Implemented : 5 Nos.
2 sec / Day
gauge for 0
K.O. system Before After
54
THEME: LOSS NO
KAIZEN
LOSS STRUCTURE:
MACHINE:
TEAM:
17B3S
KAIZEN START
To reduce Inspection 8A
time Inspection Time Reduction Jayaraman 19.03.2001
Devanathan
BENCH MARK 10 Sec / Inspection IDEA: Krishnamoorthy KAIZEN FINISH
To provide oil level visual indicator Sivakumar
TARGET 1 Sec / Inspection outside the gear box 31.03.2001

Before After
Lock Dip
screw Stick
Max
To check the oil level in gear box • Time saving / month = 270 Sec
is very difficult & take more time Gear Gear
Box Box • Timings saving / Year = 3240 Sec
• Effortless activity
Min
* Unlock Screws
* Remove Dip stick * Inspect Only
* Inspect
* Assy dip stick
* Lock screw
ANALYSIS: RESULT: HORIZONTAL DEPLOYMENT :
WHY 1 WHY 2 WHY 3 Before After
Sec
Inspection Method of Basic Area Status
10 10 Sec
the oil inspection machine
level takes
more time
is difficult design Socket ` 8/13
5
BETTER Hex ` 11/15
1 Sec
Special
` 7/13
55
Easy to Clean & Inspect
Before Motor Inside After Motor Outside
The 10b3s forging machine was fully The C’measure was taken by opening
covered which makes difficult to clean & the side cover of the machine & an See
inspect in the motor, fly wheel area thru sheet was provided which makes
easy to clean and inspect, the motor and
flywheel.
56
57
58
DIFFICULT TO INSPECT- EASY TO INSPECT

Before After
Difficult to Inspect the belt Easy to Inspect the belt condition

condition
59
Rearranging cables / hoses for easy inspection
Before After
60
Step 3: Formulation of clean-

up and lubrication standards
• Learn the structure and functions of
your own equipment (training by
leader)
• Test your understanding and then
actually inspect the equipment
• Correct new problems found
• Establish through visual controls to
help control equipment conditions 61
62
Step 3 : Preparation of Tentative “Jishu-Hozen” Standards

Purposes :
• Basic conditions of activities to prevent equipment deterioration -- Maintenance and management of
cleaning, lubrication and retightening
• Action standard allowing accurate maintenance of basic conditions quickly is prepared by oneself
• New ideas for visual control
(Steps 1 and 2)
List of slight defects © Cleaning and inspection © Lubricating
• Clarify places Maintenance
found • Lubrication places, lubrication types,
• Clarify method department
Kaizen records lubrication levels, tools
• Clarify standard • Clarify period Lubrication manual
• Clarify troubleshooting • Identify lubrication work trouble and
Check goal time • Clarify period problems
• Set goal time • KAIZEN Lubrication training
• Set goal time
Prepare standard © Study what is wrong with existing

standards
© Study why they could not be followed
© Utilize visual control Cleaning, lubrication and inspection
Guidance items
Difference with goal time
KAIZEN
KAIZEN records
Implement and confirm Activity records
Autonomous audit Circle activity report and

plant audit application
Plat audit
Passed
Activities board
•………
•……… Passed * * *
•……… © JIPM, 1987
•………
•………
63
Cleaning and Lubricating

Inspection
1) Lubrication
1) Clarify Places Places,Types,Levels,tools
2) Clarify method 2) Clarify Period
3) Clarify Standard 3) Identify lubrication work

trouble & problems, Make
4) Clarify
Lubrication Manual
Troubleshooting
4) Kaizen
5) Clarify Period
Set Goal time

64
MAJOR GUIDELINES TO PREPARE JH STANDARDS
• Study the existing M/C check sheet & Analyse the reasons,
why is it not maintained and used effectively.
• All the cause and problems should be addressed & rectified

while preparing new standards
• Set Goal time for all activities put together-Cleaning,

Lubrication, Inspection & Retightening, set it separately for
D,W,M & Y activities
• Consider Stratification of Fuguais & see to that no Fuguai is

missed, which needs to be addressed in standards to prevent
Forced deterioration
65
• Clarify place, method, standard, troubleshooting, period, tool,

frequency etc. So that no ambiguity and subjectivity remains
in mind while taking decision for any point in the standard
• The standards should be rational and should consider all

points necessary to maintain its basic operating conditions
and prevent equipment deterioration.
• Bring in More VISUAL CONTROLS so during inspection

decision can be made easily & correctly by the person about
check points.
• Revise the standards after implementing any Kaizen
66
VISUAL CONTROLS
Activity Symbol Tools
CLEAN
I
LUB
S
INSPECTION NOC
67
COLOUR CODE FOR FREQUENCY
68
DAILY INSPECTION ROUTE

BEFORE STEP-3
9 8 7
1
6
5
3 4
Machine - Shigiya 138 - Grinding Machine

69
70
71
JISHU-HOZEN CHECK SHEET

POINT NO. 3 HYDRAULIC TANK FRONT,LUB TANK,FRL AND WORK HEAD BACK
MACHINE : C P BORING CELL : CONNECTING ROD PLANT : ENGINE PLANT MONTH : JANUARY
STND.
SL. NO CHECK ITEM D W M VALUE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1 HYDRAULIC TANK FRONT

No dirt &
1a Outer body dust
No Leak
1b Pipe Joints
btwn.
Max &
1c Oil level indicator Min.
in Green
1d Oil pressure Gauge Zone
2 LUBRICATION TANK
No dirt &
2a Tank outer body dust
btwn.
Max &
2b Level indicator Min.
2c El. Jn. Wiring 3M

No Leak
2d Lub Pipe joints
Checked By :
Sign. Of Supervisor
REVISION NO. 1 2 3 4
LEGENDS - ( ) - OK , ( ) - NOT OK , ( ) - NOT OK,RECTIFIED BY SELF , ( ) - NOT OK, INFORMED SUPERVISORP, ( ) - PLANNED.
72
TENTATIVE CLEAN LUB INSPECT

STANDARDS
Cell : Nozzle Cell Jishu - Hozen ( Tentative Cleaning, Lubrication and Inspection ) Standards
Equipment description : Micromatic OD Grinding Machine Equipment number : M12045 Cirlce name : NOZH 1
Person
Tools and Time Cycle During During
Illustration Classification No. Place or section Standards Method in
handling sec (month) operation stoppage
charge
Inspection 1 Tailstock With in the indicated Visual 2 W OP b
Tail stock
value range
N
Cleaning 2 Tailstock Free from mist & dust Waste cloth
I 30 W OP b
Inspection 3 Table Lubrication With in the indicated Visual 2 W OP b
value range
N
Inspection 4 Loader Pistion No Damage Remove the 3mm 1200 1 M OP b
Pistion block Allenkey
Keys : D : Daily; W : Weekly; SC : Setting change; PM : Maintenance staff; OP : Operator.

73
Aiders : Visual controls
74
Indication marks
Indication for
for nuts & bolts
valve controls
75
Operational range Direction flow indicators

on indicators
76
Arrow sign for

Fan to indicate the
indicating the
function of Chiller Unit
rotating direction of
Motor
77
Color code for Lubrication oil Display of sub equipment name
78
79
ONE POSITION INSPECTION
Hydraulic Lube oil

tank tank
Before – Hydraulic tank and

Lubrication tank in different After – Hydraulic tank and
position. Lubrication tank in one position.
80
Initial Clean-up
( Cleaning is Inspection)
( Cleaning with meaning)
(Doing with purpose)
Taking countermeasure
for forced deterioration
and improving hard
to access area
Preparing tentative
standards for cleaning
and lubrication
81
Example of Activities Board

Leader Sub leader
Circle
Members
Section and Subsection
Goals and Measures
Policies
Themes !
Kobetsu-Kaizen
Reason for Selection Understand Present status

Accomplishment Indices
Overall Efficiency
Troubleshooting and Schedule

Analysis
Non Defe-ctive
Availability Performance Rate
Rate
Effect
Prevention of Recurrence,
Acceptance
Remaining problems
Stoppag
Rework
Failure
Defect
Speed
Minor
Jishu-Hozen
Activity Schedule
Number of Suggestions
*
Fuguai List
Efu Attaching and One-Point Lesson
Removing
“Good to Find” Corner

List of Doubts
Meetings Photo
Actual Work Activities
Before Before
Source : Our TPM

© JIPM, 1994
82
Concept of “Jishu-Hozen”
Change in concept
Defects and
failures are the
Step 1 shame of the
Step 2 Step 4 Production shop Step 6
Step 0 Step 3 Step 5 Step 7
Effect Effect Production
Change Operator’s
Motivation Reduced shop
equipment Change Zero defects
defects and changes
failures and failures are
realized
Change in activities
• Think and act • Rectify “Fuguai”
• Positive
• Process of • Cleaning is challenge for
actions is inspection KAIZEN.
head-spring of • Inspection is a step • Thoroughness of • Bottom up from circle
motives to find “Fuguai” maintenance and activities
• “Fuguai” should and management • Autonomous KAIZEN
• Why does could be restored or by operators
forced improved
deterioration • Restoration and KAIZEN are a
occur ? kind of success.
• Needs of Enhance ability to find • Success is a pleasure as a result
“Jishu-Hozen and improve “Fuguai” of achievement
(Unless success can be

expected, the operators will not
change their mind.)
83
Keypoints for Autonomous Maintenance Success and Check

Points of Controller Roles
1. Introductory education…………….…….. Is TPM well understood ?

2. Cooperation between Divisions………. Are the assistance and cooperation of other divisions
towards the production division satisfactory ?
3. Main Body of Circle Activities………….. Are the overlapping small group activities adopted ?
4. The work itself ………………………….. Has the concept of “Autonomous Maintenance is the work
itself “ been established
5. Practice – First ………………………..…. Instead of insisting on forms and theroy, are people
learning by experience ?
6. Education & Training……………………. Are training education and training done in accordance
with the step
7. Substantial effect………………………… Are substantial effects obtained in accordance with the
steps ?
8. The matters to be observed shall………. be decided by Is there the capacity to decide by oneself ?
oneself
9. Autonomous Maintenance……………… Diagnosis Are the diagnosis and guidance of the controller
adequate?
10. Model Selection………………………….. Is the selection of the model adequate ? Is the guidance of
the controller good ?
11. Rapid Processing of ………………..…… Plant Is the processing of non-conformity points and
improvements done rapidly ?
12. Make it Thorough………………………… Aren’t the steps merely followed by formality?
84
Step 4 : General Inspection

Purposes :
• Understand structures, functions, principles and proper approach of equipment
• Learn skills to inspect principal functions and parts comprising equipment
• Thoroughly inspect principal functional parts comprising equipment and actualize and restore latent
defects
• Cut model Preparations Training implementation

• Inspection © Identify subjects © Instructors
item list © Prepare teaching materials © Leaders
• Flow chart © Prepare training program © Each machine element 6 subjects
• Schematic
diagram
- 2 subjects
General inspection implementation Prepare 1- point lessons
8. Machining conditions
7. Safety
6. Electric
Transmission of education
5. Drive
4. Pneumatic
3. Hydraulic
2. Lubrication
Training
1. Bolts and nuts
General inspection manual
Comprehension check
Analysis of Inspection
results
Skill check
Restore and Prepare tentative inspection standard for
improve each subject
© Visual control Items pointed Autonomous audit for each subject Circle activity report
out
Application for plant audit

Plant audit for each subject
Activities board
See data for

Hydraul
fuguai
each subject Passed

•………
© JIPM, 1987
ic
•………
85

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TPM Club India Autonomous Maintenance Pillar

Reasons Why Autonomous Maintenance is Required

Classification of Maintenance and Responsibility

Check Quality KAIZEN

•Inspect & lubricate daily I take care of

Relationship Between Forced Deterioration and Losses

Examples of Steps for Evolving Autonomous

5 Autonomous check-up Formulation and implementation of autonomous check-up sheets

Four Steps to Become An Operator Strong on

Autonomous Four steps to

7 All-out autonomous management 4 Master how to repair the equipment

6 Orderliness and tidiness Learn how to operate the equipment

How to Concretely Develop “Jishu-Hozen”

* Establish of basic conditions (cleaning, lubrication and retightening)

* Trained operators to be proficient in equipment and reduction in failure rate

How to Concretely Develop “Jishu-Hozen” (Contd.)

* Through implementation and maintenance of inspection

How to Concretely Develop “Jishu-Hozen” (Contd.)

Step Category Activities Target Guidance and

* KAIZEN activities, including those for problems related to equipment

* Making the strong structure which can perform “Jishu-Hozen management

• Development of company • Kaizen of equipment • Enhancement of goal • Technical assistance

Step 1 - Initial Cleaning

Step 1 - Initial Cleaning : Activities

Table 4-6. Sample Manual on Exposing Seven Types of Abnormality

• Adhesion Blocking, hardening, accumulation of debris, peeling, malfunction

2. Unfulfilled Basic Conditions

Table 4-6. Sample Manual on Exposing Seven Types of Abnormality : Contd...

5. Quality Defect Sources

Unnecessary and Non-

Identification of forced deterioration

Step 2 - Measures against

Means easy to clean,

Use of localised guards

• Focus Restoration and KAIZEN KAIZEN records

Modify equipment to make cleaning easier

Install covers and inspection windows to

IDEA FOR ELIMINATING

PROBLEM: COUNTERMEASURE: BENEFITS :

Remove magnet & No cleaning remove

ANALYSIS: RESULT: HORIZONTAL DEPLOYMENT :

THEME: LOSS NO.

3 min / shift Krishnamoorthy KAIZEN FINISH

Man hours saved per year = 15 hours

No Spill Over of Products

Basic design 3 min / shift

EXAMPLES OF LOCALISED CONTAINMENT

Eliminate cleaning by fabricating chute for collecting

Actions to eliminate dust falling on the floor

Countermeasures against source of contamination

Before Machine cover After Machine cover

Pulley Pulley Grease points

Difficult to Lubricate the oil to Easy to Lubricate the oil to

THEME: LOSS NO.

Franklin KAIZEN FINISH

Man hours saved per year = 15 hours

ANALYSIS: Problem : Inspection is difficult RESULT: HORIZONTAL DEPLOYMENT :

By machine 30 sec / change

taking 15 Identified : 5 Nos.

PROBLEM: COUNTERMEASURE: BENEFITS :

Easy to Clean & Inspect

Before Motor Inside After Motor Outside

DIFFICULT TO INSPECT- EASY TO INSPECT