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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
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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
Concept of Dry floor steps
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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Concept of Dry floor steps
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
Dry floor step 1 implementation
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.
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Dry floor step 1 implementation
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
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
Dry floor Step 3 implementation
Minimize
Can I
eliminate
the source?
Collec
Localize
Methodology to contain the source of contaminationPut S No.
Empty it every day
Put 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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Dry floor Step 3 implementation
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
Assy Step 1 implementation
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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Assy Step 3 implementation
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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