Keikaku Hozen Master Plan

Step Description Year

1st 2nd 3rd 4th

1 Guidance & Support to Jishu Hozen

2 Evaluating Equipment & Grasping present Status
3 Carrying out Zero Failure activities
4 Development of Maint. Information mgt. system
5 Establishing predictive maintenance methods
6 Establishing Lubrication management activities
7 Establishing Spare parts management activities
8 Enhancing maintenance technology &skills
9 Practicing Self management
10 Evaluation of Planned Maintenance

Start End Plan continues

 Detailed Plan : Step-1
Step-1 : Guidance & Support to JH activities Year
1st 2nd 3rd 4th
1 Preparing Line Diagrams for training Operators

2 Training operators for finding abnormalities

3 Gathering Past Failures M/C wise, S/A wise, Part wise

4 Study of Past Failures and Countermeasures

5 Removing the Fugai which operator cannot remove.

6 Taking countermeasures for contamination sources and hard

to access areas.

7 Helping in making cleaning, inspection and lubrication

standards

8 Implementing visual controls in the machines to make

inspection easy and quick.

9 Preparing basic training material for different Equipment

categories

10 Training to Circle leaders about machine functions & causes

of past failures
 Detailed Plan : Step-2
Step-2 : Year
Evaluate Equipment and Grasp present Status 1St 2nd 3rd 4th

1 Create and update equipment ledger

2 Decide Equipment ranking evaluation criteria.

3 Rank all Equipments based on criticality.

4 Decide Equipment Failure ranking criteria

5 Rank all past and present failures based on criticality

6 Establish Bench mark and Targets

7 Select appropriate maintenance method

8 Review & revise existing maintenance system

9 Draft the inspection and maintenance standard procedures

10 Select parts and members for TBM activities

 Train Detailed Plan : Step-3
Step-3 : Zero failure activities Year
1St 2nd 3rd 4th
1 Training Staff / Technicians to do why – Why analysis

2 Restoring unattended deterioration & Elimination of forced

deterioration

3 Carrying out Why Ok analysis to check equipment health

4 Analyzing past failures M/c wise, Sub-Assembly wise, , part

wise, root cause wise and taking preventive actions

5 Identification & Elimination of week designs / overloading

6 Analyzing current failures & preventing re-occurrences

7 Eliminating Environmental deterioration

8 Reducing / Eliminating manual work

9 Standardizing TBM calendar & Maintenance schedule

10 Horizontal replication of of Kaizen ideas

 Detailed Plan : Step-4
Step-4 : Develop & Implement maintenance Year
information management system. (CMMS) 1St 2nd 3rd 4th

1 Build failure data management system.

2 Build & implement equipment maintenance

Management system
3 Build & implement System for spare parts
management.
4 System for maintenance budget management.

5 System for Lubrication management.

6 System for condition based maintenance
management
 Detailed Plan : Step-5
Step-5 : Establish Predictive 1st Year 2nd Year 3rd Year 4th Year
maintenance system.

1 Study the need for predictive maintenance &

Learn equipment diagnostic techniques

2 Identify components to be diagnosed based

on criticality Ranking of components

3 Find out various suitable diagnostic

techniques.

4 Prepare CBM calendar and schedule /

Implement CBM

5 Find out latest technological development in

the field of CBM

6 Research & development of in-house

diagnostic techniques.
 Detailed Plan : Step-6
Step-6 : Lubrication management 1st Year 2nd Year 3rd Year 4th Year
activities

1 Review & revise existing Lubrication

management system.

2 Establish & implement lubrication

management standards.

3 Investigate & integrate various type of

lubricants.

4 Promote visual control systems & easy to

lubricate devices to eliminate failures by oil
shortage.

5 Systematize lube. Oil purchasing & used oil

disposal management.
 Detailed Plan : Step-7
Step-7 : 1st 2nd 3rd 4th
Spare Parts Management Activities. Year Year Year Year

1 Arranging and reviewing of spare part drawings and details

2 Evaluate existing spare parts management system.

3 Establishing spare parts management criteria

(What item, What quantity)

4 Establish spare parts control standards

5 Establish replacement parts management

6 Systemize purchasing system

7 Computerize spare part management system

8 Spare parts inventory & cost control

 Detailed Plan : Step-8
Step-8 : Enhance Maintenance 1st Year 2nd Year 3rd Year 4th Year
Technology and Skills

1 Training need identification

2 Prepare Training Materials

3 Training for upgrading maintenance Skill

& knowledge

4 Training to enhance maint. Technology

Step 9 is Self Audit: make your own audit points based on the rest
of the 8 Steps. (Activities to be done in 8 steps) Step 10 is
Evaluation: Checking performance Indicators such as Equipment
failure No., MTBF, MTTR, Maintenance Cost, No.of men trained.
Etc.