TPM in Office

Safety, Health & Environment

Education & Training

Development Management

Quality Maintenance

Planned Maintenance

Focussed Improvement

Autonomous Maintenance

8 Pillars of TPM

Autonomous Maintenance

Autonomous Maintenance is the activities in

which each worker performs daily inspection,

lubrication, parts replacement, minor repair,

trouble shooting, accuracy checks etc. on his
own equipment, aiming at achieving the goal

of Keeping ones own equipment in good

condition by oneself

The Mind set ..

Individual preserving ones own equipment
Significant change from early theory of I manufacture
You repair

or

I make - You Fix

PRODUCTION

MAINTENANCE

Maintenance does not its job

They take too long to fix the equipment
This equipment is so old no wonder it
breaks down again and again
We are too busy to do vital daily checks

Production do not know how

to operate
We get lot of repairs so we
dont have ample time to do a
real corrective action and are
forced to do only temporary job
We prepare the standards but
they do not do the checks

DEVELOP

Responsible

What TO DO

Operators for Skill and Knowledge

of his equipment
To do Jishu Hozen on his equipment

Operator/Supervisor/
Officer/Manager
1. Initial Clean Up
2. Countermeasures for Contamination
Sources & Hard to do CLIT
3. Apply Tentative Standards
4. Carry Out General Inspection
5. Do General Process Inspection
6. Standardize the Activities
7. Improve & Maintain

HEINRICH TRIANGLE
Major Problem (1)

Medium Problems (29)

Minor Problems (300)

Invisible Problems (3000)

EQUIPMENT DETERIORATION
Natural Deterioration Accelerated Deterioration
Extend Life Time

Corrective Maintenance
Prevent errors by
improving operability
Improve Maintainability
& Repair Quality
Improve safety
& Reliability

Eliminate Causes

Establish Basic Condition

Cleaning : Eliminate
all dust & Dirt
Lubricating : Keep
lubricants clean and
replenished
Tightening : Keep nuts
& bolts secure

 TO PREVENT EQUIPMENT FORCED DETERIORATION

TO MAINTAIN EQUIPMENT IN OPTIMAL CONDTION

TO ESTABLISH BASIC EQUIPMENT CONDITION
TO ELIMINATE EQUIPMENT FAILURE
TO MAKE OPERATOR EQUIPMENT COMPETENT
TO ELIMINATE QUALITY DEFECTS

TO ELIMINATE COST LOSSES

Concept of Jishu Hozen

Cleaning is Inspection
Inspection is a step to find Fuguai (abnormality)

Fuguai should & could be restored or improved

Restoration & Kaizen are a kind of Success
Success is a pleasure as a result of achievement

It enhances ability to find & improve fuguai

It changes the mindset of people

AUTONOMOUS MAINTENANCE
STOP ACCELERATED DETERIORATION
CLEAN THE EQUIPMENT
IDENTIFY PROBLEM AREAS AND RECTIFY

DEVELOP/IMPLEMENT STANDARDS

BRING IT BACK TO ORIGINAL STATE

DO IMPROVEMENTS

IDENTIFY AND ELIMINATE CHRONIC PROBLEMS AND

HARD TO ACCESS AREAS
DEVELOP/IMPLEMENT STANDARDS

IMPROVE IT FURTHER
KNOW YOUR MACHINE WELL
INNOVATE AND IMPLEMENT NEW IDEAS

7 Steps of Autonomous Maintenance

Autonomous Management
Standardization
Autonomous Inspection
General Inspection
Preparing Tentative Cleaning, Lubrication, Inspection & Retightening Stds.
Countermeasures against Sources of contamination & Hard to Access areas

Initial thorough Cleaning

Preparation

Familiarization with the equipment and its current condition

1S/2S activities on and around the equipment
Understanding Forced Deterioration & Need for Autonomous Maint.

Understanding Equipment (Simple illustrations of the Equipment)

Safety (listing of all unsafe conditions & safety training)

Skill Needs for Initial Cleaning & finding abnormalities (Step-1)

Past Problems of the equipment (failures, defects, complaints etc.)/OEE

Preparation of TPM Circle Activity Board

5S
SEIRI

SORTING

SEITION

SYSTEMATISING

SEISO

SHINING (Cleaning)

SEIKETSU

STANDARDISING

SITSUKE

SELF-DESCIPLINE

SAMPLE

Line Diagram showing Dirt/leakage map

TO COOLING TOWER

SERVICE WATER LINE

F.W.PUMP

DELIVERY
VALVE
N. R .V

DELIVERY
VALVE

ICW LINE
V.T.
PUMP
F.W.PUMP DELIVERY HEADER

SCALE PIT # 2 PUMP PIT

GREASE SPILLAGE
WATER LEAKAGE
OIL LEAKAGE

LISTING OF THE PAST PROBLEMS OF THE TPM CIRCLE

SN

Problem description

Frequency

Total Time Lost

STATUS OF THE SAFETY AND PROTECTIVE DEVICES

Sl.
No Name of the Safety/Protective Device

Present Status
Checking Standard (OK/ Not OK)

Response (if not OK)

Target
Date

MONITORING OF OEE
OEE
Base Level
Current Avg.
Target

33.60
59.65
93.10

100
90.0

75

65.0

50

Nov

Sep

Jul

May

Mar

Jan

25

Quality Rate

Performance Rate

Availability
Base Level
Current Avg.
Target

60.00
80.75
95.00

Base Level
Current Avg.
Target

70.00
82.08
98.00

80.00
89.00
100.00
95.0

100

100

100.00

Base Level
Current Avg.
Target

90.0
81.0

75.00
75

70.0

75

50.00
50

50

25

25

Nov

Sep

Jul

May

Mar

Jan

Nov

Sep

Jul

May

Mar

Nov

Sep

Jul

May

Mar

Jan

0.00

Jan

25.00

Activitiy Board
Jishu Hozen summary of
abnormalities & analysis

Circle Name:

Loss Structure

Team Memebrs:

Results trend on Various attributes 1. Red & white tag status

of P, Q, C, D, S & M
2. Human Vs Equipment weakness

Equipment Schematic
Diagram

(Kobetsu Kaizen) Process Themes:

Identified, Solved & Status

TPM Targets
Jishu Hozen and Planned
P, Q, C, D, S, M Base values, Maintenance immediate plan for
Benchmark & Targets
next 3-4 months

Master Plan
(next 3-4 Years)

Audit Results:
Jishu Hozen and Planned
Maintenance
Audit Dates planned:
C, L, I, & R standards
Summary of Why Why Analysis
(cause vs number of analysis) ,

One Point Lessons (month vs

Numbers) and Kaizens (m onth vs
Num bers)

matrix
3. Area-wise equipment weakness
4. Abnormality type wise stat

Before and After Photographs

Process Theme for the Month:
Detailed action Plan with
responsibilities
One Point Lessons
Detailed Plan for the month of
various pillar activities
Kaizen Sheets
Why Why analysis Sheets
Communication point:
Meeting Notice (Date, Venue,
Agenda & Tim e) , Other
communication between
members etc.

Example of Activities Board

Leader

Members

Circle

Section and
Subsection Policies Goals and
Measures

Sub leader

Kobetsu-Kaizen

Themes !

Reason for Selection

Understand Present
status

Analysis

Troubleshooting and
Schedule

Jishu-Hozen Activity schedule

Accomplishment Indices

Overall Efficiency

*
Fuguai List
One-Point
Lesson

Availability

Performance
Rate

Non Defective Rate

Effect

Prevention of
Recurrence,
Remaining problems

List of Doubts

Good to Find Corner

Rework

Before
Defect

Minor
Stoppage

Speed

Failure

Acceptance

Photo

Number of Suggestions

Efu Attaching
and Removing

Actual Work

Meetings
Activities

Before

One Point Lesson

TPM Circle
Prepared by:
T heme
Classification
(
W hich ever is
applicable)

Sl. No.

Preparation Date

Basic Condition
Trouble Case
Improvement Case

W hat Condition is Abnormal

W hy the condition is Abnormal

W hat will happen if continuously used
without correcting Abnormality
Troubleshooting

Date Executed
Teacher
Student

TPM Circle Details

Department :

Cold Rolling Mill

TPM Circle :

PLTCM Welder

Team Details
Mr.
Mr.
Mr.
Mr.
Mr.
Mr.

A Chakraborti
A Behera
A Chadnani
K Kant
J Sinha
P Kumar

Circle Meeting

Facilitator
Leader
Member
Member
Member
Member

: Every Monday 3 PM

MASTERPLAN
TPM Circle : PLTCM WELDER (CRM)

sample

MONTH
1S/2S ACTIVITY & VISUAL MANAGEMENT
JISHU HOZEN
JH STEP ZERO
JH STEP ONE
JH STEP ONE AUDIT
JH STEP TWO
JH STEP TWO AUDIT
JH STEP THREE
JH STEP THREE AUDIT

Apr May Jun Jul Aug Sep Oct Nov Dec

Jishu Hozen Step - 0

Activities Performed

Present Status

Jishu Hozen training imparted

Completed

Understanding the equipment

(sketch/line diagram of machine)

Completed

Safety related training imparted

Completed

1S/2S activities on the machine

Under Progress

Historical data of the machine

(Failures (freq./duration),defects etc.

Under Progress *

Activity Board Maintenance

Yes

* Show the line diagram/historical data on next slides

7 Steps of Autonomous Maintenance

Autonomous Management
Standardization
Autonomous Inspection
General Inspection
Preparing Tentative Cleaning, Lubrication, Inspection & Retightening Stds.
Countermeasures against Sources of contamination & Hard to Access areas

Initial thorough Cleaning

Preparation

Cleaning & Inspection to Expose Abnormalities

Follow Safety Instructions
Open Cover (do not dismantle) for Cleaning

Touch and Clean every Corner

Clean not only Equipment but also accessories
Cleaning is for Inspection

Find Abnormalities and Faulty Places

Attach tags (Red / White) to abnormalities identified
Restore abnormalities on the spot whichever are possible
Analyze abnormalities for root causes & develop
countermeasures (Kaizens)
Remove tags if abnormalities are restored.

Cleaning consists of removing old dust, dirt,

grime, oil, grease and other contaminants that
adhere to equipment and accessories , in
order to find fuguais (abnormalities) and
expose defects.

Responsibility Allocation & Drawing Schedule

Provide Basic Training to Initiate Step-1
Allocating places for cleaning (Equipment + Accessories) to all members,
based on their skill.

Detailed Cleaning Plan (Map)

Leader to explain plan to all members
Schedule for all places given to members

Month
`Name
Day 1
AA

Adjusting schedule for other works.

BB
CC

Day 2

Day 3

JISHU-HOZEN PLANNING SHEET FOR STEP-1 CLEANING

TPM Circle/ Equipment Name:
Equipment Parts

Sub-Assemblies

Man-hour
needed

Members

Month:
1

Legend:

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Name of Members:
1.

Planning
2.

Cleaning & Fuguai Identification

3.

Summerization

4.

Analysis & Identifying Countermeasures

5.

Implementing Countermeasures

6.

Shutdown Dates
Format: 3.2

JISHU HOZEN PLANNING SHEET FOR STEP -1 CLEANING

Equipment: Laying Head
Assembly

Components

Members

30 31 1

Month: April
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

B. C. Sadhukhan

Motors & Couplings

R. L. Dubey
B. Debraj

Gear Box

H. K. Chaturvedi

Gear Assembly
Hood & Trippe
plate

Daljeet Singh
Mohan Singh

M. M. Sridhar

Hydraulic system

G. S. Chatterjee

Legend:

Members:
Mohan Singh

Planning

B. C. Sadhukhan
R. L. Dubey

Cleaning & Fuguai Identification

Summerization
Analysis & Identifying Countermeasures
Implementing Countermeasures

B. Debraj
H. K. Chaturvedi
Daljeet Singh
M. M. Sridhar
G. S. Chatterjee

Shutdown Dates

CLASSIFICATION OF FUGUAIS
Equipment Weakness

Human Weakness

1.Minor Flaws

1. Non Observance of Basic

Condition

2.Unfulfilled Basic conditions

3.Sources of Contaminations
4.Hard to Access areas

2. Non Observance of Used

Condition

5. Quality Defets

3. Leaving deterioration
unattended

6.Non urgent Items

4. Design Weakness

7.Unsafe places

5. Shortage of Skills

1.MINOR FLAWS
2. UNFULFILLED BASIC CONDITIONS
3. INACCESSIBLE PLACES
4. CONTAMINATION SOURCES
5. QUALITY DEFECT SOURCES
6. UNNECESSARY AND NON-URGENT ITEMS

7. UNSAFE PLACES

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

2. UNFULFILLED BASIC CONDITIONS

Lubrication
Lubrication
Supply
Oil level gauges
Tightening

Insufficient, Dirty, Unidentified, unsuitable,

Leaking
Dirty, damaged or deformed lubricant inlets,
faulty lubricant pipes
Dirty, Damaged, leaking, No indication of
correct level
Nuts and Bolts slackness, Missing, Crossthreaded, Too long, Crushed, Corroded,
Unsuitable washers, wing nuts on backward

3. INACCESSABLE PLACES
Cleaning
Checking

Machine construction, Covers, Layout, footholds,

Space
Construction,
Covers,
Layout,
footholds,
Instrument position and Orientation, Operating
Range display

Lubricating Position of lubricant inlet, construction, height,

footholds, lubricant outlets, space
Tightening
Operation

Covers, Construction, Layout size, Space

Machine layout, Position of valves, Switches and

levers, Footholds
Adjustment Position of pressure gauges, thermometers, flow
meters, moisture gauges, vacuum gauges, etc.

4. CONTAMINATION SOURCES
Product
Raw materials

Leaks, Spills, Spurts, Scattering, Overflow

Leaks, Spills, Spurts, Scattering, Overflow

Lubricants

Leaking, Spills, Seeping oils, Hydraulic fluids,

Fuel oils, etc.
Leaking compressed air, gases, steam, vapors,
exhaust fumes, etc.
Leaking water, Hot, Cold, half finished
products, Waste water, Leaking supply lines etc.
Flashes, cuttings, packaging materials, and non
conforming products.
Contaminants by people & Forklifts, Infiltration
through cracked walls, broken windows etc.

Gases

Liquids
Scrap
Others

5. QUALITY DEFECT SOURCES

Foreign Matter Dust, Rust, powder, chips, moisture, wire
scraps, wood pieces, paper pieces, stones etc.
Shock
Dropping, Jolting, collision, Vibration etc.

Moisture
Grain Size
Concentration
Viscosity

Too little or Too much, infiltration

Abnormalities in screens, Compressed air
separators, centrifugal separators,
Inadequate warming, heating, compounding,
mixing, evaporation, stirring etc.
Inadequate warming, heating, compounding,
mixing, evaporation, stirring etc.

6. UNNECCERY AND NON-URGENT ITEMS

Machinery
Pumps, fans, compressors, columns, tanks etc.
Piping equipment Pipes, hoses, ducts, valves, dampers etc.

Measuring
instruments
Electrical
equipment
Jigs & Tools

Temperatures, pressure gauges, vacuum

gauges, ammeters etc.
Wiring, piping, power leads, switches, plugs
etc.
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.

7. UNSAFE PLACES
Floors
Steps
Lights
Rotating
machinery
Lifting
Devices
Others

Unevenness, cracked, holes, projections, peeling,

wear of steel chucker plates, slipping.
Too steep, irregular, slipping, missing handrails, etc.
Dim, out of position, dirty or broken covers, no
explosion proofing, etc.
Displaced, fallen oil or broken covers, not safe for
emergency, missing emergency stop devices
Wires, hooks, brakes and other parts of cranes and
hoists etc.
Special substances, solvents, toxic gases, insulating
materials, danger signs, protective clothing etc.

HARMFUL EFFECTS OF INADEQUATE CLEANING

Failure

Dirt and foreign matter penetrates rotating parts, sliding

parts, pneumatic and hydraulic systems, electrical control
systems and sensors etc., causing loss of precision,
malfunction and failure as a result of wear, blockage,
frictional resistance, electrical faults etc.

Quality
Defects

Quality Defects are caused either directly by contamination

of the product with foreign matter or indirectly as a result of
equipment malfunction.

Accelerated
Deterioration

Accumulated dust and grime make it difficult to find and

rectify cracks, excessive play, insufficient lubricants, and
other disorders, resulting in accelerated deterioration.

Speed Losses

Dust and dirt increase wear and frictional resistance causing

speed losses such as idling and under performance.

Checkpoints for Nuts & Bolts

Slight
Loose nuts & bolts, missing nuts & bolts
defects
Bolt length All bolts should protrude from nuts by 2-3 threads

Washers

Fixing of
nuts &
bolts

Are flat washers used on long holes

Are tapered washers used on angle bars & channels
Are spring washers used for parts subjected to
vibration
Are identical washers used in identical parts
Are bolts inserted from below, are they visible from
outside
Are devices such as limit switches fastened at least
by 2 bolts
Are wing nut direction clock wise

Lubrication checkpoints
Lubricant
storage

Are lubricant sores always kept clean, tidy, are 5S principles

applied
Are lubricant containers always capped
Are lubricant type clearly indicated and is proper stock control
practiced

Lubricant
inlets

Are grease nipples, speed reducer lubricant ports and other

lubricant inlets always kept clean
Are lubricant inlets dust proofed
Are lubricant inlets labeled with correct type and quantity of lub.

Oil level
gauges

Are oil level gauges always kept clean, are oil levels easy to check
Is the correct oil level clearly marked
Is equipment free of oil leaks, and oil pipes& breathers
unobstructed

Auto Lub
Devices

Are Auto lubricating devices operating correctly & supplying

correct quantity of lubricants

Lubricatin Are rotating, sliding parts, and transmission well lubricated

g condition Are the surroundings free of contamination by excess lubricant

Transmission System checkpoints

V-Belts &
Pulleys

Are any belt cracked, swollen, worn out, or contaminate by lub.

Are any belts twisted or missing. Are any belts stretched or slack
Are multiple belts under uniform tension and all of the same type
Are top surfaces of belts protruding above the pulley rims? Are the
bottoms any pulley groves shiny (indicating a worn belt or pulley)
Are pulleys correctly aligned

Roller
chains

Are any chains stretched 9indicating worn out pins or bushings

Are any sprocket teeth worn, missing or damaged
Is lubrication between pins and bushings sufficient
Are sprockets correctly aligned

Shafts,
Is there any overheating, vibration, abnormal noise due to excessive
Bearings & play, or lack of greasing. Are any keys or set bolts loose or missing
Couplings Are any couplings misaligned or wobbling, Are any seals worn out
Gears

Are gears rightly lubricated with proper amount of lubricant.

Are any teeth missing, damaged worn out or jammed
Is there any unusual noise or vibration

Hydraulic checkpoints
Hydraulic
Checkpoints

Is there correct quantity & level indicated for fluid in the reservoir
Is fluid of correct Temp. And is min & max for temp. indicated
Is fluid cloudy (indicating air entrapment
Are all fluid inlets & strainers clean, are any suction filters blocked
Are any fluid reservoir breather filters blocked
Are fluid pumps operating without any unusual noise or vibration
Are hydraulic pressure correct, and are operating ranges displayed

Heat
Exchangers

Is any fluid or water leaking from fluid coolers or pipes

Are temp. differences between fluid & water inlets & outlets are
correct ? Are any tubes blocked

Hydraulic
Equipment

Are there any fluid leaks ? Are hydraulic properly fastened?

Are hydraulic devices operating correctly without speed loss or
breathing? Are hydraulic pressure correct? And all gauges working

Piping and
Wiring

Are all pipes and hoses fastened tightly?

Are there any fluid leaks? Are any hoses cracked or damaged?
Are all valves operating correctly? Is it easy to see whether valves
are open or closed/ Are any pipes, valves unnecessary?

Pneumatic checkpoints
FRLs

Are FRLs clean? Is it easy to see inside of them? Are they fitted
right way around?
Is there sufficient oil. And are the drains are clear?
Is the oil dip rate correct ?(approx 1 drop for every 10 strokes)
Are the FRLs installed not more than 3 m from the equipment?
Are the pressure adjusted to the correct value and operating ranges
are clearly indicated?

Pneumatic
Equipment

Is compressed air leaking from pneumatic cylinders or solenoids?

Are all pneumatic cylinders and solenoid valves firmly fastened?
Are any pistons dirty, worn, damaged?
Are the speed controllers installed right way around?
Is there any abnormal sound or overheating of solenoid valves, and
are any lead wires chafed or trailing?

Piping and
Wiring

Are there any places in pneumatic pipes or hoses where fluid is

liable to collect? Are all hoses and pipes clipped firmly in place?
Are any hoses cracked, damaged, are there any air leaks?
Are valves operating correctly and open and close position known

Electrical Checkpoints
Control
Panels

Are the interiors of distribution boards, switch boards, and control

panels kept clean, tidy, and well organized by the application of 5S
activities? Have any objects or flammable materials been left inside
Is the wiring inside control panels in good condition? Are any wires
coiled or trailing?
Are all ammeters and voltmeters operating correctly?
Are any switches, bulbs broken? Do all switches work correctly?
Are panel doors in good condition? Do they Open & close easily?
Are there any unused holes? Are control panels water& dustproof?

Electrical
Equipment

Are all motors free of overheating, vibration, unusual noise & smell
Are al motor cooling fans and fins are clean?
Are any bolts loose? Are pedestals free of cracks and damages?

Sensors

Are all manual switches clean and free of damages & excessive play
Are all switches installed in the correct position
Are the interiors of limit switches is clean? Are any wires coiled or
trailing?
Are any limit switch dogs worn, deformed, or of the wrong shape?

Electrical Checkpoints Cont.

Sensors

Are all photoelectric switches and proximity switches clean and

free of excessive play?
Are any sensors out of position? Are correct positions clearly
indicated?
Are all lead wires un-chafed, and is insulation intact at entry
points?

Switches

Are all switches installed in the correct position

Are all manual switches clean and free of damages & excessive
play
Are emergency stop switches installed in appropriate locations
and are they in good working condition?

Piping and Are any pipes, wires, or power leads loose or unsecured?
Wiring
Are any ground wires damaged or disconnected?
Are any pipes damaged or corroded? Are there any bare wires
or wires with damaged insulation?
Are any wires coiled on the floor or dangling overhead?

CLASSIFICATION OF ABNORMALITIES (FUGUAI)

(Human-being Weakness)
Type

Classification

Non-fulfillment of
Basic Conditions

II

Non-observance of
Use Conditions

III

Leaving deterioration
unattended

IV

Inherent design
weaknesses

Shortage of
Skills

Description

Insufficiency of cleaning, oiling and tightening

Although use conditions for facilities and

equipment exist and set at the design stage,
such conditions are not observed.
Example : Electric current, voltage, number of
rotations, temperature, speed etc.

Fail to identify deterioration and to restore

correctly, i.e. not conducting correct inspection/
examination or preventive repair to restore
original conditions of equipment

Lack of technical expertise at the stages

of design, manufacturing, and work execution,
as well as errors

Repair errors and operational errors

EXAMPLE OF ABNORMALITY
( LOOSE FITTINGS )

EXAMPLE OF ABNORMALITY
( LEAKAGES )

White tags for operators

Red Tags to be attended by Maint.

Equipment Name

Equipment Name

Control No..

Control No..

Date of detection.

Date of detection.

Detected by..

Detected by..

Description of Minor defects

Description of Minor defects

..

..

ABNORMALITY [FUGUAI] IDENTIFICATION SHEET

Equipment Weakness
A';
Major Flaws
B:
Unfulfilled Basic conditions
C
Inaccesible Areas
D
Contamination sources
E
Quality Related Defects
F
Unnecessary & onourgent items
G
Unsafe palce

Human Weakness
I : Non-observance of basic conditions
II. Non-observance of Use Conditions
III. Leaving Deterioration unattended
IV. Inherenet Design Weakness
V : Shortage of Skills

Compliance Date

Target Date

Responsibility

Countermeasures
Urgency
(U/SD/MSD)

Causes of
Abnormality

Impact of
Abnormallity

Tag (R/W)
Eqpt Weakness
(A..G)
Human Weakness
(I..V)

Abonrmality
Description

Location

PERIOD:

Part of Equipment

Date of Detection

Sl. No.

TPM CIRCLE

IMPACT
1. Breakdowns
2. Readjustments
3. Quality
4. Safety & environment
5. Others

ABNORMALITY [FUGUAI] IDENTIFICATION SHEET

TPM CIRCLE :-H5 TPM CIRCLE (Hot Strip Mill)

Sl. No.

Date of
Part of
Abonrmality
Location
Detection Equipment
Description

Tag
Red/
White

*Eqipment ** Human Impact of

Causes of
Counter
Weakness weakness Abnormali
Abnormalities Measures
(A...G)
(IV)
ties

8/5/01

CJC FILTER Cellar

Filter is not
properly fixed

8/5/01

CJC FILTER Cellar

Piping not ok

III

8/5/01

ELC filter

Piping not ok

III

II

No
indication

II

Cellar

8/5/01

Cooler

Cellar

8/5/01

Illumination

Cellar

8/5/01

Electrical
wiring

Cellar

8/5/01

Lighting

Cellar

8/5/01

RC pump

Cellar

8/6/01

Cellar

Cellar

Temperature
gauge
mounting not
ok
Celler light not
ok
Wiring are not
ok
Tube light
wiring
defective
Wiring are not
ok
Illumination is
not sufficient

Envoironme
Design defect
nt
Hard to
Ignorance
access
Hard to
Design defect
access

***
Urgency TARGET Complian
U/SD/
DATE ce Date
MSD

Base to be
modified

SD

20-Aug-01 15-Aug-01

Accesibility

SD

20-Aug-01 20-Sep-01

Piping to
modify

SD

20-Aug-01 20-Aug-01

Loosness

To be tighten

20-Aug-01 20-Aug-01

Vissibility

Safety

To provide extra
SD
light

20-Aug-01 20-Aug-01

II

False
indication

Ignorance

To be set right

SD

20-Aug-01

II

5S

Ignorance

To be set right

20-Aug-01 20-Aug-01

II

Loose
Trippage of
connection motor

SD

20-Aug-01 20-Aug-01

Unsafe
condition

10-Aug-01

* Equipment Weakness
** Human Weakness
A';
Minor Flaws
I : Non-observance of basic conditions
B:
Unfulfilled Basic conditions
II. Non-observance of Use Conditions
C
Inaccesible Areas
III. Leaving Deterioration unattended
D
Contamination sources
IV. Inherenet Design Weakness
E
Quality Related Defects
V : Shortage of Skills
F
Unnecessary & nonourgent items

Bulb fused

New wiring to
be done
Provide
sufficient
illumunation

IMPACT
1. Breakdowns
2. Readjustments
3. Quality
4. Safety & environment
5. Others

8-Aug-01

*** URGENCY
U- Urgent
SD- Shutdown
MSD- Major Shutdown

SUMMARY OF ABNORMALITIES
A
Sl.
No
I

II

III

IV

Category

Non Observance of
Basic Conditions
Nonobervance of Use
Conditions
Leaving deteriorations
unattended
Internal Design
Weaknesses
Shortage of Skills

TOTAL

Major
Flaws

B
C
D
Unfulfilled Inaccessible Source of
Basic
areas
conditions

E
F
G
Source Unnecessary Unsafe

contamination Quality & non

places
Defects urgent items

SUMMARY OF ABNORMALITY
TPM CIRCLE: - Compactor
Category
A
B
C
D
E
F
G
Sl.no
Equipment weakness Minor Flaws Unfulfilled Inaccessible Source of
Source Unnecessary Unsafe
Basic
areas
contamination Quality & non
places
Human weakness
conditions
Defects urgent items
I

II Nonobervance of Use Conditions

III
IV
V

Non Observance of Basic Conditions

Leaving Deteoriration Unattended

19

11

12

Internal Design Weakness

Shortage of Skills

Total

12

Total

13

10

61
Format 3.4

Thorough Cleaning
(Touch and Clean every Corner)

Lists

List of
Defects

List of
Hard to Access Areas

List of
Sources of contamination

List of Questions

List of
Unnecessary & Nonurgent Items

Analyze Abnormalities &

Planning Countermeasures
Gathering the data on Abnormalities & Faulty Places
Analyzing the Abnormalities for the root cause and
Decide countermeasures
Develop Countermeasures & Kaizen action plan.
Fixed deadlines to be stated on tags.

Follow up plan at least weekly, disseminate information

to all members.

Jishu Hozen Step - 1

Activities Performed

Present Status

Jishu Hozen training imparted

Completed

Cleaning Plan prepared

Done

Initial Thorough cleaning of machine

and identification of fuguais

Completed

Classification and summary of fuguais

Under Progress *

* Show the cleaning plan, Fuguai identification sheet &

summary matrix in next slides

ABNORMALITY STATUS CATEGORY WISE

SAMPLE

250

No. of Abnormalities

200

150

100

50

0
Minor Flaws

Unfulfilled Basic Inaccessable

Condition
Area

Source of
Quality Defect
Contamination
Sources

Type of Abnormality

Unecessary
Items

Unsafe Places

Identified

Corrected

Jishu Hozen Audit

Step 1: Initial Cleaning

Audit

Item

1. Cleaning of
Equipment
Main Body

2. Cleaning of
subequipment
[Oil,
Pneumatic &
hydraulic
pressures;
Electrical
systems]

Self

JH Pillar
Committe
e

Section/
Team name
Equipment Name

Date

Desired Audit date

Point
Accepted
Rejected
Acceptable level =
Sum of(Item 1-5 level point) + Evaluation point (Item 6)

Audit Date
TPM Central Auditor
Group
Description

Leader

Self
More than 90 points

JH Pillar Committee
More than 85 points

TPM Central Grou

More than 80 poin

Bad

Passable

Excellent

1 Point

Poor
2 Point

3 Point

Good
4 Point

5 Point

How Well are the dust, oil and grease, and chips removed? How about the
condition of work and tools? (Such areas as tools and jigs surfaces, chucks,
sliding portion, chute, frame, bed, piping and wiring etc.)
Free from loosening, chattering, vibration, exessive wear and heat buildup (in
areas as bolts, nuts, jigs, rotation portions, sliding portions and chute etc.)
Free from dust, oil and grease or any other foreign materials(cylinder, solenoid,
three point set, motor limit switch, belt, proximity switch, photoelectric tube,
inside & outside of control box, instruments, etc.)
Free from loosening, chattering, vibration, exessive wear and heat buildup
(motors, solenoid valve, limit switch installation board, relay, wiring, bolts and
nuts etc.)
Free from dust,dirt and oil stain (Lubricator, oil cups, measuring instruments, cap
of oil filter, oil supply piping, etc.)

3. Lubrication

Proper oil level and oil flow rate, free from loosening, chattering, and vibration.
(Check for contaminated oil, oil deterioration, loose piping joints, valve, speed
control, oil temperature etc.)
Cleaning condition of tools, measuring instruments and gauges and spare parts
Are the covers, name plate and label in good condition? Are the unnecessary
parts, products and replacements parts in good order?

4. Cleaning
around the
equipment and
Are the accepted products properly segregated from rejected products?
machine
Are the proper passages provided?
No flying dust from adjacent equipment?
5. Counter
measures for
the causes of
dirty
equipment and
improving hard
to access
areas

Has any list showing the sources of dust, dirt, oil leakage and the areas difficult
to keep clean been prepared?
And it there any future plan for cleaning?
Have the cover and houe keeping utensils been improved?
Is there any point you should check while performing the house keeping?
Has the responsibility for cleaning the areas been properly assigned to each
operator?

6. Employment Has TPM been weel understood and

of TPM
are all members participating in the
Technique
activities?

Evaluation point
Diagnosis

10 point

20 point

30 point

40 point

50 point

7 Steps of Autonomous Maintenance

Autonomous Management
Standardization
Autonomous Inspection
General Inspection
Preparing Tentative Cleaning, Lubrication, Inspection & Retightening Stds.
Countermeasures against Sources of contamination & Hard to Access areas

Initial thorough Cleaning

Preparation

Purpose of Step-2

Eliminate sources of contamination that

generate dirt & stains
To improve places which are difficult to access
for cleaning, lubrication, inspection, tightening
Enable Learning in doing JH Kaizens
Improve Visuals on the equipment

Devising countermeasures
to Eliminate
Sources of Contamination

Hard to Access Areas

Time consuming Places
Places difficult to work

Eliminate the Source

Eliminate Need to Access
Contain (localize)
the Contaminant
Shield (Protect) the
Affected part
Improve
Cleaning Method

Reduce
need to
(Frequency)

Improved
Method of
C, L, I & R

approach

Less Time & Effort

Improve Accessibility

ELIMINATING SOURCES OF CONTAMINATION

ELIMINATE THE POINT GENERATING THE
CONTAMINATION.
I
IF THE ABOVE IS NOT POSSIBLE, CONTAIN THE
CONTAMINATION BY DOING KAIZENS.
IF BOTH THE ABOVE ARE NOT POSSIBLE,
DEVELOP A CLEANING STANDARD TO RETAIN THE
CONTAMINATION WITHIN THE PERMISSIBLE LIMIT.

Jishu Hozen : Step-II

SOURCES OF CONTAMINATION

TYPE OF CONTAMINATION

Product

Leaks, spills, Spurts, Scatters, Overflow

Spillage, Scattered on ground

Lubricants
Gases

Leaking, Silt, seeping oils

Leaking Compressed Air / Gases etc.
Leaks, Spurts, Scatters, Overflow

Liquids
Scrap
Other

Flashes, Cuttings, Papers etc.

People, Forklift Trucks etc.

Date of Completion

Planned Date

Executor

Contents of
Countermeasures

Type of
Contamination

Source of
Contamination

Part of Equipment

Date of
Observation

Sl. No

LIST OF SOURCES OF CONTAMINATION

LIST OF SOURCES OF CONTAMINATION

Department: - Hot Strip Mill

Sl.No.

TPM CIRCLE: __________________

Date of
Part of
Source of
@Type of
Responsi Planned Date of
Countermeasures
Observation Equipment Contamination Contamination
bility
Date Complition

4/10/01

Surrounding

Gland leakage.

Seeping oil.

4/10/01

Pump tray.

Filter changing.

Spillage oil.

20/09/01

Ace Stand.

Leaking joints

Leaking oil.

20/09/01

Level/Pr.
Gauge.

Atmosphere dust

Dust

Gland seal to be
repaired every 2 year
To be cleaned just
after job is over
Pipe joints to be
checked once a year
To be cleaned on
every shutdown.

@ TYPE OF CONTAMINATION
Leaks,Spills,Spurts,Scatters,Overflow, dust
Spillage,Scattered on ground
Leaking,Silt,Seeping oils
Leaking Compressed Air/Gases etc.
Leaks,Spurts,Scatters,Oveflow
Flashes,Cutting,Papers etc.
By people,Forklift,Truck etc.

TPM
CIRCLE
S.K.Ojha

20/02/2002

20/02/2002

28/01/2002

4/2/02

S.K.Ojha

15/02/2002

15/02/2002

R.K.Purbe. 15/02/2002

15/02/2002

EXAMPLES OF LOCALISED CONTAINMENT

Before

After

Usage of
localized guards

Countermeasures against source of contamination

Oil Localisation
Before

After

Localised guards
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

HARD-TO ACCESS-AREAS
WHILE DOING STEP 1, MANY AREAS MAY BE FOUND,
WHICH ARE DIFFICULT FOR CLEANING, INSPECTION
AND LUBRICATION. ACCESSIBILITY OF THESE AREAS
NEED TO BE IMPROVED THROUGH SUITABLE KAIZENS.
- PROVIDE INSPECTION POINTS FOR EASE OF
INSPECTION.
- PROVIDE PROPER INSPECTION WINDOWS FOR THE
PARTS LIKE V-BELTS

- PROVIDE SPACE/REACH TO CLEAN PARTS

- PROVIDE TOOLS/TACKLES TO LUBRICATE

LIST OF HARD TO ACCESS AREAS

* Difficult state:
X- Less difficult
Y- Moderate difficult
Z- Very Difficult

** Tag
R- Red,
W- White

Date of Completion

Planned Date

Responsibility

Tag Classification **

Contents of
Countermeasures

TPM Circle : _________________________

Difficult State *

Difficult Portion

Categories C,L,I

Date of Observation

Sl. No.

Department : ________________

LIST OF HARD TO ACCESS AREAS

Department: - Hot Strip Mills

Sl No.

Date of
Categories
Observati Cleaning (C),
on
Lubrication (L),
Inspection (I)
4/11/01

25/12/01

5/1/02

TPM CIRCLE: Down Colier # 1

Difficult
Portion

Acc. Stand.
(Height)

Aproch to
tank top
due to
loose hose
pipe
Cleaning
not
possible of
ELC & CJC
Base

* Difficult state:
X- Less difficult
Y- Moderate difficult
Z- Very Difficult

Difficult
State*

Countermeasures

One Permanent Steel

Plateform to be made for
aproach during N2
checking & Filling.
All hose pipe to be
modify to steel pipe

** Tag Responsi Planned

Classificat bility
Date
ion (R/ W)

Date of
Complition

V.K.Sinha 15/02/02

20/02/02

S.K. OJha MSD 2002

1/5/02

R.K. Purbe 28/02/02

28/02/02

New base to be made of

CJC & ELC filter unit
Z

** Tag
R- Red,
W- White

DIFFICULT TO LUBRICATE
- EASY TO LUBRICATE

Before
Difficult to Lubricate the oil to
gear box

After
Easy to Lubricate the oil to
gear box

DIFFICULT TO INSPECT- EASY TO INSPECT

Before

Difficult to Inspect the belt

condition

After

Easy to Inspect the belt condition

Why - Why Analysis

Breakdown / Physical Phenomenon:

Question

Answer

What is your Final Action, so that it is OK

WHY

ANSWER

ACTION

Why Did you take above action

Due to

Action needed

Why 1
Why 2
Why 3
Why 4
Why 5

Root Cause
(1)
(2)
(3)
(4)
(5)

JH

PM

Design

Poor Basic Condition

Poor Operating Condition
Deterioration
Weak Design
Poor Skill

NOTE: This Form is to be filled immediately after the machine is started

E&T

Why - Why Analysis

Breakdown / Physical Phenomenon: Cylinder doesn't Operate Smoothly

Question

Answer

What is your Final Action, so that it is OK Cleaning Strainer

After Cleaning Strainer is it OK
Yes

WHY

ANSWER

ACTION

Why Did you take above action

Due to

Action needed

Why 1

Why did you clean the strainer

Strainer was clogged

Clean strainer

Why 2

Why strainer was clogged

Oil was dirty

Drain oil and Clean

Why 3

Why oil was dirty

Dirt enter in the tank

Prevent scatering of chips

and cutting fluid

Why 4

Why does dirt get in

Why 5

Why was hole made

Root Cause
(1)
(2)
(3)
(4)
(5)

Upper plate of tank has hole

Plug hole and gap
and gap
Repair error during
Standardize repairs
maintenance work

JH

PM

Poor Basic Condition

Poor Operating Condition
Deterioration
Weak Design
Poor Skill

NOTE: This Form is to be filled immediately after the machine is started

Design

E&T

KAIZEN IMPLEMENTATION SHEET

THEME :-

IDEA :-

TPM CIRCLE :-

KAIZEN No.:

DATE:
BEFORE :-

AFTER :-

BENEFIT :-

ANALYSIS :-

RESULT :-

HORIZONTAL PLAN :Machine

Plan
Comp.

KAIZEN IMPLEMENTATION SHEET

THEME:REDUCE

IDEA:TO UPGRADE FILTERS AND INSTALL OIL

EQUIPMENT FAILURE
BY IMPROVING OIL
CLEANLINESS

CLEANING M/C

BEFORE:

AFETR: ELC M/C INSTALLED AND UPGRADED THE BENEFIT:

PROPER FILTERATION
SYSTEMS WERE NOT
AVAILABLE TO
MAINTAIN OIL
CLEANLINESS LEVEL OF
NAS VALUE 6

TPM CIRCLE:

KAIZEN NO: 1

CASTER #1 HYD ROOM

DATE:10.03.02

FILTERS
MODIFIED 5 MICRON
ELC M/C FOR TANK
FILTERS
OIL CLEANING

CYLINDER SEAL CONSUMPTION

25
20

NOS

15
10
5
0

NO OF DRIVE CYL SEAL CONSUMED

01-02

NAS LEVEL OF CASTER OIL

10

MACHINE: CAN BE IMPLEMENTED IN

CASTER#2 &3

8
6

PLAN:TO BE IMPLEMENTED BY OCT

2002

4
2

COMPLIANCE: IMPLEMENTED IN
ACTUAL

IDEAL

D
EC

V
N
O

C
T
O

SE
P

AU
G

JU
LY

JU
N
E

M
AY

AP
R
IL

M
AR
C
H

FE
B

0
JA
N

WHY SEAL FAILS?

PRESENCE OF FINE
DIRTS IN OIL
WHY DIRTS IN OIL ?
POOR OIL
CLEANLINESS
WHY POOR OIL
CLEANLINESS?
ABSENCE OF
PROPER OIL
CLEANING SYSTEM

HORIZONTAL PLAN:

RESULTS:
12
NAS VALUE

ANALYSIS:

02-03

BOTH CASTERS

THEME:

KAIZEN

LOSS NO

MACHINE:

LOSS STRUCTURE:
To reduce Cleaning time
BENCH MARK

30 Sec

TARGET

5 Sec

8A

Cleaning Time Reduction

COUNTERMEASURE:
Before
Oi
lC

Cleaning the contaminated

material deposited in the magnet
takes more time

hu

Contaminated
material
te

KAIZEN START

TEAM:

IDEA:
To provide a polythene paper on the
magnet to collect contaminated material

PROBLEM:

13B5SL

S.Ravindharan
V.Mohan
P.Comarasen
K.Patchaiappan

15.03.2001
KAIZEN FINISH
16.03.2001

BENEFITS :
After
Oi
lC

hu

Contaminated
material
te

Polythene
Magnet
Paper

Magnet

Time saving / month

= 533 min

Timings saving / Year

= 6396 min

Effortless activity
Oil tank
Remove magnet &
cleaning by brush with
diesel then fix magnet

ANALYSIS:
WHY 1
Cleaning
the
magnet
takes
more
time

Oil tank
No cleaning remove
Polythene paper and fix
new polythene paper

HORIZONTAL DEPLOYMENT :

RESULT:
WHY 2

WHY 3

Iron
particles
not
coming
out
easily
from
magnet

Due to
magnetic
property

Sec
30

Before

After

30 Sec

BETTER
15
5 Sec
0

Area

Status

Socket

13

Hex

15

Special

13

THEME:

KAIZEN

LOSS NO.

To Reduce Cleaning Time inside the

machine area in rolling machine

BENCH MARK

8A

LOSS STRUCTURE:
Cleaning Time Reduction

CGR17H

TEAM: J. Srinivasan

KAIZEN START
03-06-2001

S.Jayaraman

3 min / shift

IDEA:
To provide gaurds in the product discharge chute &
providing conveyor

Zero

TARGET

MACHINE:

PROBLEM:

COUNTERMEASURE:
Before

Krishnamoorthy
D.Sivakumar

KAIZEN FINISH
21-06-2001

G. Devanathan
BENEFITS :

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

Product
spillover
ANALYSIS:
WHY 1

Cleaning time

Problem : Cleaning time is more

WHY 2

WHY 3

Products get

Basic design

is more in

spilled over

inside the

inside the

machine area

machine area

in rolling

and oil leakage

machine

from chute

No oil leakage

Oil

S-Conveyor
Oil Pit

RESULT:

HORIZONTAL DEPLOYMENT :

mts
3 min / shift
3

Better

of chute

No of rolling machines
Identified

: 9 Nos.

Implemented : 6 Nos.
Zero
0

Before

After

Target Date

25-09-2001

THEME:

KAIZEN

LOSS NO.

LOSS STRUCTURE:

To reduce Inspection time

BENCH MARK
TARGET

MACHINE:

8A

2 sec / Day

PROBLEM:

Inspection Time Reduction

COUNTERMEASURE:
Before

KAIZEN START

TEAM: J. Sriram

10.05.2001

Karunairaja

IDEA:
To bring the pressure gauge for K.O. system outside the
machine for easy inspection

30 sec / Day

10B3S

After

Franklin

KAIZEN FINISH
25.05.2001

Sivakumar
Ramalingam
BENEFITS :

Time saving = 28 sec / Day

Man hours saved per year = 15 hours

Inspection is very difficult and

taking more time in the pressure
gauge for K.O. system

Pressure
gauge
Inside the M/c

Difficult to
Inspect
ANALYSIS:
WHY 1

Inspection is
very difficult
and it is
taking

Problem : Inspection is difficult

WHY 2

WHY 3

Pressure gauge

By machine

kept inside the

design

Pressure
gauge
Outside the M/c

Other Benefits
Inspection becomes easy

Easy to
Inspect

RESULT:

HORIZONTAL DEPLOYMENT :

Sec.
30 sec / change
30

Better

No of Areas

machine

Identified

15

: 5 Nos.

moretime in
pressure
gauge for
K.O. system

2 sec / Day
0

Before

After

Implemented : 5 Nos.

IMPROVEMENT IN VISUALS ON THE EQUIPMENT

Points / Ideas to create Visual Workplace
(To Create Orderly Shop Floor)

Level Indicators, Meters, Gauges, Dials

1.

Oil level indicator for levels

2. Red, Orange and Green zones on gauges, meters for Go, Take Corrective Action and No
Go Situations
3.

Gauges on all pressure line close to the point of use

4.

Transparent covers for panels, belts to show direction

Covers, Drives, Doors

1. Acrylic sheets to expose closed drives
2. Transparent doors wherever possible
3. Install Inspection holes on safety covers.
4. Provide inspection windows for critical moving parts.
5. Where sight glasses are used, make sure that they are clean and High / Low points are boldly
marked and colour coded, so as to see at a glance.

6. Identify Covers, which are removable by colours coding them.

Possible points of
Application

Jishu Hozen Audit

Step 2: Countermeasures for the
causes of forced deterioration and
improving Hard-to-Access Area
Audit

TPM Circle

Section/
Team name
Equipment Name

Date

Desired Audit
date

Point
Accepted
Points = Sum of Item 1-6 points

Rejected

Audit Date

TPM Circle

TPM Central Group

JH Team TPM Centarl Auditor

Group

Item

Description

1. First Step
Maintenance State

Is cleaning level of first step (Initial Clean up) good, and

is it maintained?
Are the cause sources such as dirt, dust, oil leakage,
air leakagesummarized into a list, and are
countermeasuresfor the causes taken?

2.
Countermeasures
for equipment main Are the hard to clean areas summarized into a list, and
are the state of contrivance and KAIZEN good?
body
(Are cleaning tool covers removed, put in orderliness
and tidiness?)

3.
Countermeasures
for sub-equipment

4. Cleaning around
the equipment and
machine

5. KAIZEN and
maintain

Are the causes trouble such as dirt, dust, oil leakage,

air leakage summarized into a list, and are
countermeasures for the causes taken?
Are the hard to clean areas summarized into a list, and
are the state of contrivance and KAIZEN good?
(Are cleaning tool covers removed, put in order and
neat?)
Are the cause sources such as dirt, dust, oil leakage,
air leakage summarized into a list, and are
countermeasures for the causes taken?
Are the hard to clean areas summarized into a list, and
are the state of contrivance and KAIZEN good?
(Are cleaning tool covers removed, put in order and
neat?)
Are the oil labels attached in accordance with the
lubrication control standards so that any body can
perform lubrication?
Is every body participating in the activity?

6. Activity State

Are they taking advantage of the independency in the

kaizen activity?

Section Chief

Leader

JH Team

More than 90 points

More than 85 points

More than 80 points

Bad

Passable

Excellent

2 Point

Poor
4 Point

6 Point

Good
8 Point

10 Point

Remarks

7 Steps of Autonomous Maintenance

Autonomous Management
Standardization
Autonomous Inspection
General Inspection
Preparing Tentative Cleaning, Lubrication, Inspection & Retightening Stds.
Countermeasures against Sources of contamination & Hard to Access areas

Initial thorough Cleaning

Preparation

Continuous Maintenance and Management of Basic Equipment Conditions

Prepare Standards for Cleaning, Lubrication, Inspection & Re-tightening

Places & Location

Schedule/Frequency

Method

Tools & Jigs to be used

Standard/Level

Target Time

Enhancing Equipment Reliability & Maintainability

Preparing standards that can be followed easily
Use of Visual Control
Kaizens for reduction in time

C, L, I, R Standards
Implementing Cleaning, Lubrication,
Inspection, & Retightening Standards
Gap with target time
Kaizen (Implement & Confirm)
Feedback

Audit
Passed

VISUAL CONTROLS
Activity
CLEAN

LUB

INSPECTION

Symbol

Tools

I
S
NOC

DAILY INSPECTION ROUTE

BEFORE STEP-3

7
6

5
3

Machine - Shigiya 138 - Grinding Machine

TPM J.H : KEY POINTS OF ACTIVITY

(PROCESS)
5.5-4.1 A

EXAMPLE OF TENTATIVE STANDARD

JISHU-HOZEN TENTATIVE STANDARDS

Group: Comp
Leader: Sudip.Das
Tag:ME/Comp/202

(Inspection,Cleaning,Lubrication,Tightening)
Location:Compressor House
Equipment:Compressor-1
mast er ! A 1

Part

DESCRIPTION

STANDARD

METHOD

TOOL

Prepared : 1.10.2001
Revised : 4 times

ACTION If Time
Abnormal (min)

IN T E R V A L

RESP

DY
Alt

W M

I-1

OIL LEVEL IN
TANK

B etween lo w & high level

mark o f sight glass.

--

FILL TO
MARK

HH,NM

I-2

LOA DING &

UNLOA DING
SYSTEM

110A= loading
65A=Unloading

--

Inform
P.M

SD,AD

I-3

TANK OIL

No sediments

--

Replace

10

I-4

BLOW-DOWN
VALVE

NO JAMMING

--

I-5

OIL STOP VALVE

NO JAMMING

IN
IN
IN

C-1

AFTER COOLER

NO DUST OR OIL
SPILLS

WIPE

NO DUST

WIPE

NO DUST
NO DUST OR OIL
SPILLS

WIPE

NO DUST

WIPE

Comp air

NO DIRT

WIPE

Comp air

Inform
P.M
Inform
P.M
Inform
P.M
Inform
P.M
Replace
Inform
P.M
Inform
P.M
Replace

NO DIRT

WIPE

Replace

NO DIRT

WIPE

Comp air

NO DIRT

WIPE

Comp air

NO DIRT

WIPE

Comp air

NO DIRT

WIPE

Comp air

NO DIRT OR OIL
SPILLS

WIPE

CRC,CTC

Inform
P.M
Inform
P.M
Inform
P.M
Inform
P.M
Inform
P.M

N
IN

@
@

C-3

SUCTION
STRAINER
AIR FILTER

C-4

M/C OVER ALL

C-2

C-5
C-6
C-7
C-8
C-9
C-10

MOISTURE
TRAPPER
MAIN OIL FILTER
BEARING OIL
FILTER
LOADING
SOLENOID
UN-LOADING
SOLENOID
ACTUATOR

OIL COOLER
INSIDE
CONTROL PANEL
C-12
INSIDE
FERULE JOINTS IN
T-1
PIPE
TYRE COUPLING
T-2
BOLTS
C-11

NO LEAKS
NO SLACKNESS

--

Comp air

WIPE

HH,AR

AK, NMu

10

AK,JLG

10

JLG, KM

SD,AK

DP,JLG

15

NMu, AR

BPB,AR

15

HH,NM

15

BPB,AR

15

SD,AD

15

SD,DP

15

AK,JLG

120

JLG, KM

120

AD,KB

Replace

10

DP,AK

Inform
P.M

15

SD,AK

TPM J.H : KEY POINTS OF ACTIVITY

(PROCESS)
5.5-4.1 B
master!A1

EXAMPLE OF TENTATIVE STANDARD

JISHU-HOZEN TENTATIVE STANDARD (CLEANING, CHECKING & LUBRICATION)
GROUP - JH
EQUIPM ENT:- SLAG GRANNULATION, SHELL& TUYERE PUM P

Prepared 12/11

LEADER -D.BANDYOPADHYAY
Revised : nil

Location:- PUM P -HOUSE

PART
PUMP
1.1 PUMP
BASE
1.2 BRG.
HOUSING

STA NDA RD

2.3
TERMINAL
& PANEL
BOX
3.
COUPLING
4.PULLEY
5. BELTS
6, VALVES

ACTION IF
ABNORMAL

TIME
(MIN)

INTERVAL
D

NO VIB RA TION &

NOISE
NO
OVERHEA TING(>80
DEG C), NO
A B NORM A L SOUND
NO
OVERHEA TING(>80
DEG C), NOISE

1.3 CASING
2.1 MOTOR NO VIB RA TION &
BASE
NOISE
2.2 MOTOR
BODY

METHOD TOOL

NO DIRT OR OIL
SP ILLS

I
I
@

NO OVERHEA TING

NO LEA KA GE

KNR,

SRC, KNR,
SA

INFORM TO
P/M

GCP, SC, RC

DB, GCP

10

GCP, GN,
KNR

INFORM TO
P/M

INFORM TO
P/M
INFORM TO
P/M
INFORM TO
P/M

ARD, SB,SA

NO ODOUR

RESP

INFORM TO
P/M

INFORM TO
P/M
INFORM TO
P/M

WIPE

NO LOOSENESS
NO
OVERHEA TING(>80
DEG C), NOISE

INFORM TO
P/M
INFORM TO
P/M

10

5
2

SB,ARD,SA
SB,ARD,SA

SB,ARD,SA

DB,ARD,SB

LUBRICATI
ON
LUBE
POINT

STA NDA RD

2.5 M OTOR
B RG. DE

70% FULL WITH

LUB RICA NT

2.6 M OTOR
B RG. NDE

70% FULL WITH

LUB RICA NT

70% FULL WITH

LUB
1.5 P UM P B RG.
DERICA NT
70% FULL WITH
LUB
RICA NT
1.4 P UM P B RG.
IM P
70% FULL WITH
LUB RICA NT
1.6 GLA ND
70% FULL WITH
LUB RICA NT
1.6 B RG. HOUSING

LUB E
TYP E &
QTY

AP-2 &
20 gms
AP-2 &
20 gms
AP-2 &
20 gms
AP-2 &
20 gms
AP-2 &
20 gms

METHOD TOOL

TIME

INTERVAL

RESP
GCP, KNR,
SC
GCP, KNR,
SC

manual

manual

manual

A RD, SB ,TB

manual

A RD, SB ,TB

manual

A RD, SB ,TB

SRC,SA , DB

HOULIC 68manual
& 500 M L

TENTATIVE CLEAN LUB INSPECT

STANDARDS
Jishu - Hozen ( Tentative Cleaning, Lubrication and Inspection ) Standards

Cell : Nozzle Cell

Equipment description : Micromatic OD Grinding Machine

Illustration

Tail stock

Classification

Inspection

No.

Equipment number : M12045

Place or section

Tailstock

Standards

With in the indicated

Cirlce name : NOZH 1

Method

Visual

value range
Cleaning

Tailstock

Free from mist & dust

Waste cloth

Inspection

Table Lubrication

With in the indicated

Visual

value range
Inspection

Loader Pistion

No Damage

Tools and Time Cycle

handling

N
I
N

Remove the

3mm

Pistion block

Allenkey

sec (month)

Person
in
charge

OP

30

OP

OP

1200 1 M

OP

During

During

operation stoppage

b
b
b
b

Keys : D : Daily; W : Weekly; SC : Setting change; PM : Maintenance staff; OP : Operator.

Aiders : Visual controls

Indication marks
for nuts & bolts

Indication for
valve controls

Fan to indicate the

function of Chiller Unit

Arrow sign for

indicating the
rotating direction of
Motor

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

Jishu Hozen Audit

Step 3: Preparation of
tentative "Jishu Hozen"
Standard
Audit

TPM Circle

Item

1. Step 1 & 2
maintenace
condition
Item

Section/ Team
name
Equipment Name

Date

Equipment Name

Leader

Desired Audit date

Point

Accepted

Rejected

Team Name:
Audit Date

JH Team TPM Central

Group

Auditor

Description

Audit Date:

TPM Circle

JH Team

TPM Central Group

More than 90 points

More than 85 points

More than 80 points

Bad

Poor

Passable

Good

Excellent

3 Point

6 Point

9 Point

12 Point

15 Point

1 point

2 point

3 point

4 point

5 point

Remarks

2 point

4 point

6 point

8 point

10 point

Remarks

Remarks

Are the 1st Step's (Initial Cleaning) conditions and 2nd

Step's improvement level maintained?
Description

(Cleaning Standard)
Is the standard made out according to the equipment
and location?
Are Cleaning section, location and assignment
specified?
2. Action standard Are methods and tools specified?
Are cleaning time and cycle properly specified and
for the basic
observed?
equipment
maintenance
Are contents clear and understandable by everybody?
(Cleaning,
(Lubrication Standard)
Lubrication,
Are kind of lubrication, amount, cycle, method and
retightening)
assignment specified?
requirements
Are proper labels applied to lubrication points?
Is the oil ready for lubrication all the time?
Is the storage location tidy?
(Retightening)
Are bolts and nuts loose?
Are there any nuts and bolts that have fallen out?
Item
Description
Are the items to be observed determined
autonomously.
3. Awareness of
one's own role in Is the maintenance observed in accordance to the
making the
standard.
standard
Are the improvement and new ideas for easy
inspection and visual inspection implemented actively?

7 Steps of Autonomous Maintenance

Autonomous Management
Standardization
Autonomous Inspection
General Inspection
Preparing Tentative Cleaning, Lubrication, Inspection & Retightening Stds.
Countermeasures against Sources of contamination & Hard to Access areas

Initial thorough Cleaning

Preparation

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

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

Step 5: Autonomous Inspection

Autonomous Inspection is the actual transfer

of responsibility for equipment inspection.

Step 6 : Process Discipline

Process discipline is defined as the
establishment or improvement of methods
and procedures that enable efficiency and
repeatability. The objectives include:

Reducing set-up times.

Decreasing manufacturing cycle time.
Reduce Work in Progress.
Institute Visual Control and Inspection Method.

Step7 : Independent Autonomous

Maintenance
Independent Autonomous Maintenance is
the point at which the AM process becomes
self-sustaining.