jishu hozen or autonomous maintenance
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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
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
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
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
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
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
Fan to indicate the
function of Chiller Unit
Arrow sign for
indicating the
rotating direction of
Motor
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
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