Mr. Deepak Sahoo

Consultant

Mr. Deepak Sahoo

Consultant

•TO MAKE OPERATOR EQUIPMENT COMPETENT

•TO ELIMINATE COST LOSSES

•TO ELIMINATE Quality Defects

•TO ELIMINATE EQUIPMENT FAILURE

•TO ESTABLISH BASIC EQUIPMENT CONDITION

•TO MAINTAIN EQUIPMENT IN OPTIMAL CONDTION

•To PREVENT EQUIPMENT DETERIORATION

Mr. Deepak Sahoo

Consultant

EQUIPMENT DETERIORATION

Accelerated DeteriorationNatural Deterioration

Corrective Maintenance

• Prevent errors by

improving operability

•Improve Maintainability

& Repair Quality

• Improve safety

& Reliability

Establish Basic Condition

• Cleaning : Eliminate

all dust & Dirt

• Lubricating : Keep

lubricants clean and

replenished

• Tightening : Keep nuts

& bolts secure

Extend Life Time Eliminate Causes

Mr. Deepak Sahoo

Consultant

Mr. Deepak Sahoo

Consultant

PREVENTIVE MEDICINE FOR EQUIPMENT =

PREVENTIVE MAINTENANCE

Preventive

Medicine

Daily

Prevention

Health

checkup

(Diagnosis)

Early

treatment

Daily maintenance

(lubricate, clean,

adjust, inspect

Inspection

(Diagnosis)

Make preventive

repairs (advance

replacement)

Preventive

Maintenance

Prevents

deterioration

Measures

deterioration

Repair

deterioration

Mr. Deepak Sahoo

Consultant

Maintain

CLASSIFICATION OF MAINTENANCE ACTIVITIES

Improve

Prolong equipment life

Reduce maintenance hours

Eliminate maintenance

Preventive maintenance

Breakdown maintenance

Corrective maintenance

Improvement of maintainability

Improvement of reliability

Maintenance prevention

Normal operation

Daily maintenance

Periodical maintenance

Predictive maintenance

Design which does not need maintenance

Maintenance activities

preventing & repairing failure

Mr. Deepak Sahoo

Consultant

CLASSIFICATION OF DEFECTS

Physical latent defects Psychological latent defects

Defects which are left unnoticed due to

insufficient knowledge and education of

operators or maintenance people

The defects which are left unattended

since they are not physically exposed to

naked eyes

1. Operator or maintenance man’s

indifference

1. Defects which can not be visually

observed unless the equipment is

dismantled

2. Operator or maintenance man is not well

familiarized with types of defects

2. Defects which can not be visually

noticed due to improper installation

location of equipment

3. Operator or maintenance man’s ignorance

based on their own judgment

3. Defects which are likely to be ignored

since they are covered with dust or they

are heavily soiled

Mr. Deepak Sahoo

Consultant

7. UNSAFE PLACES

1.MINOR FLAWS

2. UNFULFILLED BASIC CONDITIONS

3. INACCESSABLE PLACES

4. CONTEMINATION SOURCES

5. QUALITY DEFECT SOURCES

6. UNNECCERY AND NON-URGENT ITEMS

Mr. Deepak Sahoo

Consultant

1.MINOR FLAWS :

Contamination Dust, Dirt, powder, oil, grease, rust, paint

Damage Cracking, crushing, deformation, chipping,

bending,

Play Shaking, falling out, tilting, eccentricity, wear,

distortion, corrosion,

Slackness Belts, Chains

Abnormal

Phenomenon

Unusual noise, overheating, Vibration, strange

smells, discoloration, incorrect pressure or

current

Adhesion Blocking, hardening, accumulation of debris,

peeling, malfunction

Mr. Deepak Sahoo

Consultant

2. UNFULFILLED BASIC CONDITIONS

Lubrication Insufficient, Dirty, Unidentified, unsuitable,

Leaking

Lubrication

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,

Unsuitable washers, wing nuts on backward

Mr. Deepak Sahoo

Consultant

Cleaning Machine construction, Covers, Layout, footholds,

Space

Checking Construction, Covers, Layout, footholds,

Instrument position and Orientation, Operating –

Range display

Lubricating Position of lubricant inlet, construction, height,

footholds, lubricant outlets, space

Tightening Covers, Construction, Layout size, Space

Operation Machine layout, Position of valves, Switches and

leavers, Footholds

Adjustment Position of pressure gauges, thermometers, flow

meters, moisture gauges, vacuum gauges, etc.

3. INACCESSABLE PLACES

Mr. Deepak Sahoo

Consultant

Product Leaks, Spills, Spurts, Scattering, Overflow

Raw materials Leaks, Spills, Spurts, Scattering, Overflow

Lubricants Leaking, Spills, Seeping oils, Hydraulic fluids,

Fuel oils, etc.

Gases Leaking compressed air, gases, steam, vapors,

exhaust fumes, etc.

Liquids Leaking water, Hot, Cold, half finished

products, Waste water, Leaking supply lines etc.

Scrap Flashes, cuttings, packaging materials, and non

conforming products.

Others Contaminants by people & Forklifts, Infiltration

through cracked walls, broken windows etc.

4. CONTEMINATION SOURCES

Mr. Deepak Sahoo

Consultant

Foreign Matter Dust, Rust, powder, chips, moisture, wire

scraps, wood pieces, paper pieces, stones etc.

Shock Dropping, Jolting, collision, Vibration etc.

Moisture Too little or Too much, infiltration

Gain Size Abnormalities in screens, Compressed air

separators, centrifugal separators,

Concentration Inadequate warming, heating, compounding,

mixing, evaporation, stirring etc.

Viscosity Inadequate warming, heating, compounding,

mixing, evaporation, stirring etc.

5. QUALITY DEFECT SOURCES

Mr. Deepak Sahoo

Consultant

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 & 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.

6. UNNECCERY AND NON-URGENT ITEMS

Mr. Deepak Sahoo

Consultant

Floors Unevenness, cracked, holes, projections, peeling,

wear of steel chucker plates, slipping.

Steps Too steep, irregular, slipping, missing handrails, etc.

Lights Dim, out of position, dirty or broken covers, no

explosion proofing, etc.

Rotating

machinery

Displaced, fallen oil or broken covers, not safe for

emergency, missing emergency stop devices

Lifting

Devices

Wires, hooks, brakes and other parts of cranes and

hoists etc.

Others Special substances, solvents, toxic gases, insulating

materials, danger signs, protective clothing etc.

7. UNSAFE PLACES

Mr. Deepak Sahoo

Consultant

7 Steps of Autonomous Maintenance

Initial thorough Cleaning

Countermeasures against Sources of contamination & Hard to Access areas

Preparing Tentative Cleaning, Lubrication, Inspection & Retightening Stds.

General Inspection

Autonomous Inspection

Standardization

Autonomous Management

Preparation

Mr. Deepak Sahoo

Consultant

Z

E

R

O

S

T

E

P

• PREPARE A CLEANING & LUBRICATION MAP

• ARRANGE TOOLS

• ARRANGE RED & WHITE TAGS

• HISTROY OF FAILURES

• TRAINING ON 7 STEPS OF JISHU HOZEN

• TRAINING ON 7 TYPES OF ABNORMALITIES

Mr. Deepak Sahoo

Consultant

• CLEANING IS INSPECTION

• USE 5 SENSES FOR CLEANING

• FIND OUT 7 TYPE OF ABNORMALITIES

• PUT TAGS ON ABNORMALITIES

• PREPARE LIST OF UNFULFILLED BASIC

CONDITIONS

Mr. Deepak Sahoo

Consultant

Equipment Name ………………

Control No……………………..

Date of detection……………….

Detected by……………………..

Description of Minor defects

………………………………….

…………………………………..

………………………………….

White tags for operators

Equipment Name ………………

Control No……………………..

Date of detection……………….

Detected by……………………..

Description of Minor defects

………………………………….

…………………………………..

………………………………….

Red Tags to be attended by Maint.

Mr. Deepak Sahoo

Consultant

• MAKE THE LIST OF

• HARD TO CLEAN,

• HARD TO LUBRICATE,

• HARD TO TIGHTEN,

• HARD TO INSPECT,

• HARD TO ADJUST

•RECORD CLEANING TIME

• CARRY OUT AUDIT ON 1ST STEP

• MEETING AFTER THE DAILY ACTIVITIES

• REFER TO THE OLD HISTORY RECORDS

Areas / Parts

Mr. Deepak Sahoo

Consultant

Mr. Deepak Sahoo

Consultant

Mr. Deepak Sahoo

Consultant

Mr. Deepak Sahoo

Consultant

EXAMPLE OF ABNORMALITY

( LOOSE FITTINGS )

Mr. Deepak Sahoo

Consultant

EXAMPLE OF ABNORMALITY

( LEAKAGES )

Mr. Deepak Sahoo

Consultant

RELAY

TRAINING

Mr. Deepak Sahoo

Consultant

Purpose of Step-2

Eliminate sources of Contamination

To improve places where it is difficult to access for cleaning, lubrication,

inspection

Improved maintainability of Equipment

Enable Learning in tackling Equipment Kaizen

Mr. Deepak Sahoo

Consultant

COUNTERMEASURES AGAINST SOURCES

OF CONTEMINATION AND HARD TO DO

CLITA

STEP 2

• COUNTERMEASURES AGAINST SOURCES OF

CONTAMINATION

• MAKE APPROACH EASY FOR CLITA

• MAKE EASY TO DO CLITA

• SHORTEN CLEANING , LUBRICATING TIME

• ADOPT CONCEPTS OF LOCALIZED GUARDS

• RANKING THE PRIORITY PLACES FOR DAILY

CLEANING

Mr. Deepak Sahoo

Consultant

Analysis ofGenerating Sources

•Understand why do they generate?

•Impact on Equipment

•Confirm the basic countermeasures

Finding & Confirmation of Generating Sources

•Understand contaminations relationship

with Quality, Failures, Maintainability

etc.

•Locate contamination generating sources

Hard to Access Areas

•Time consuming Places

•Places difficult to do.

Analyzing Hard to Access areas

• What type of work is performed?

• What tools are used?

• Can work be performed in visible state?

Mr. Deepak Sahoo

Consultant

Devising countermeasuresto Eliminate

Sources of Contamination

Hard to Access Areas

Time consuming Places

•Places difficult to do.

Eliminate the Source

Contain (localize)

the Contaminant

Shield (Protect) the

Affected part

Improve

Cleaning Method

Eliminate Need to Access

Reduce

need to

(Frequency)

approach

Improved

Method of

C, L, I & RLess Time & Effort

Improve Accessibility

Mr. Deepak Sahoo

Consultant

Easy to clean

Mr. Deepak Sahoo

Consultant

SOURCE OF CONTAMINATIONS

Mr. Deepak Sahoo

Consultant

Usage of localised guards

Mr. Deepak Sahoo

Consultant

Easy to lubricate

Mr. Deepak Sahoo

Consultant

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

Countermeasures against source of contamination

Before After

Oil Localisation

Localised gaurds

Mr. Deepak Sahoo

Consultant

Difficult to Lubricate the oil to

gear box

Easy to Lubricate the oil to

gear box

DIFFICULT TO LUBRICATE

- EASY TO LUBRICATE

Before After

Mr. Deepak Sahoo

Consultant

Easy to Inspect

Mr. Deepak Sahoo

Consultant

To reduce Inspection time 8A

30 sec / Day

2 sec / Day

WHY 1

Inspection is

very difficult

and it is

taking

moretime in

pressure

gauge for

K.O. system

WHY 2

Pressure gauge

kept inside the

machine

WHY 3

By machine

design

Inspection Time Reduction

To bring the pressure gauge for K.O. system outside the

machine for easy inspection

Before After

Before After

30 sec / change

0

15

30

J. Sriram

Karunairaja

Franklin

Sivakumar

Ramalingam

10B3S

Sec.

10.05.2001

25.05.2001

Problem : Inspection is difficult

Inspection is very difficult and

taking more time in the pressure

gauge for K.O. system

KAIZENTHEME: LOSS NO.

BENCH MARK

TARGET

LOSS STRUCTURE:

IDEA:

MACHINE:

TEAM: KAIZEN START

KAIZEN FINISH

BENEFITS :COUNTERMEASURE:PROBLEM:

ANALYSIS: RESULT: HORIZONTAL DEPLOYMENT :

Better

No of Areas

Identified : 5 Nos.

Implemented : 5 Nos.

After

2 sec / Day

Pressure

gauge

Inside the M/c

Pressure

gauge

Outside the M/c

Difficult to

Inspect

Easy to

Inspect

Time saving = 28 sec / Day

Man hours saved per year = 15 hours

Other Benefits

Inspection becomes easy

Mr. Deepak Sahoo

Consultant

Mr. Deepak Sahoo

Consultant

DIFFICULT TO INSPECT- EASY TO INSPECT

Difficult to Inspect the belt

condition

Easy to Inspect the belt condition

Before After

Mr. Deepak Sahoo

Consultant

Purpose of Step-3

Continuously Maintaining and Management of Basic equipment conditions,

(I.e. Cleaning, Lubrication, Retightening)

Enhancing Equipment Reliability & Maintainability

Preparing standards that can be followed easily

Ideas for Visual Improvement

Mr. Deepak Sahoo

Consultant

Cleaning, Inspection, Lubrication & Retightening

Clarification of places & location by all

Deciding tools, jigs to be used

Decided the method

Decide Standard / Level

Identify Problems & decide Trouble Shooting

Clarify Period

Set Goal Time

Prepare Standards &

Calendar (Schedule)

Use of Visual Control

Visual ways to allow correct

decision in short span of time on

the spot by only seeing

Mr. Deepak Sahoo

Consultant

Implementing Cleaning, Lubrication,

Inspection, & Retightening

Difference with Goal Time

Kaizen (Implement & Confirm)

Audit

Passed

C, L, I, R Standards

Feedback

Mr. Deepak Sahoo

Consultant

STEP 3

• STANDARDS FOR CLEANING, LUBRICATING

AND TIGHTENING

• STANDARDS ARE MADE BY OPERATORS

THEMSELVES WITH GUIDENCE BY PM

• STANDARDS ARE MADE BY USING 5W 1H

• STANDARDS SHOULD BE EASILY UNDERSTOOD

BY EVERY ONE

• INTRODUCE EXTENSIVE VISUAL CONTROLS

Mr. Deepak Sahoo

Consultant

CLEANING LUBRICATION & INSPECTION STANDARDS

Sl.

No.

Route

ReferenceCriteria

Sub -

AssemblyWhere What How Time

Responsibility

(Who)

Remarks

(Impact of

overlooking)

1 CleaningDual Ext.

steel beltSteel belt Dust & dirt 20 Sec Operator Quality defect

2 LubricationDual Ext.

skiver

Driven roll

bearingEP-2 grease 30 Sec Operator

Equipment

failure

3 Inspection Head stockInside pull

out ringNo damage 5 Sec Operator UNSAFE

Cleaning activities : Lubrication activities : Inspection activities :

Mr. Deepak Sahoo

Consultant

VISUAL CONTROLS

ToolsSymbolActivity

NOCINSPECTION

SLUB

ICLEAN

Mr. Deepak Sahoo

Consultant

Indication marks

for nuts & boltsIndication for

valve controls

Mr. Deepak Sahoo

Consultant

Fan to indicate the

function of Chiller Unit

Arrow sign for

indicating the

rotating direction of

Motor

Mr. Deepak Sahoo

Consultant

Mr. Deepak Sahoo

Consultant

Mr. Deepak Sahoo

Consultant

Mr. Deepak Sahoo

Consultant

Mr. Deepak Sahoo

Consultant

Avoid such extremes with some over enthusiastic teams

Mr. Deepak Sahoo

Consultant

Purpose of Step-4

Bringing up equipment consciousness in the process of measuring & restoring

deterioration.

To understand structures, functions & principles of equipment & learn their

optimal conditions to thoroughly check principal mechanisms & parts of the

equipment

Mr. Deepak Sahoo

Consultant

Preparation for Education & Training

Identifying general Inspection Items

Basic Items:

Machine Elements Lubrication system Bolts & Nuts

Hydraulic System Pneumatic System Driving Systems

Electrical systems Equipment Safety Process Conditions

Additional Items: Specific to the Equipment

Preparation of text for General Inspection Education & Training

Schedule Planning for General Inspection Education & Training

Mr. Deepak Sahoo

Consultant

Implementation of General Inspection

Education & Training

Implementation of Education for Circle Leaders

Preparation of education transmission to Circle Members

Implementation of education transmission to Circle Members

Implementation of General Inspection

Preparation of Abnormalities List for Circle Meetings Discussion & Planning Countermeasures

Restoration of Abnormalities List

Implementation of General Inspection

Mr. Deepak Sahoo

Consultant

Prevention of Irregularities in General Inspection Items

Inspection skill Check

Autonomous Audit & Application for receiving diagnosis

Preparation of Temporary Criteria for Daily Inspection

Implementation of Audit

Solutions to the Items Pointed out

Mr. Deepak Sahoo

Consultant

Prevention of Irregularities in General Inspection Items

Inspection skill Check

Autonomous Audit & Application for receiving diagnosis

Preparation of Temporary Criteria for Daily Inspection

Implementation of Audit

Solutions to the Items Pointed out

Mr. Deepak Sahoo

Consultant

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

Mr. Deepak Sahoo

Consultant

Four Steps to Become An Operator Strong on

Equipment And Autonomous Maintenance

Four steps to

become an operator

strong on equipment

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

6 Orderliness and tidinessLearn how to operate the

equipment with the required

accuracy and how to evaluate

the product quality5 Autonomous check-up

4 General inspection

3 Formulation of clean-up and lubrication

standards

2 Measures against sources of outbreaks

1 Initial clean-up

Study the mechanism and

functions of equipment and

machines

Familiarize with the concept of

equipment maintenance and

improvement and with how to put the

idea into practical realization

1

2

3

Autonomous

Maintenance

7 steps