5th TPM National Conference

Session B : Jishu Hozen (Autonomous Maintenance)

Topic :
JH Step 1-4

Presentation by

Mr Pravas Kumar Mohapatra Dy Manager Birla Tyres

Birla Tyres

JH Step 1-4

UP RO O G

B K BIRLA GRO UP O F C O MPANIES

A PRESENTATION ON "JISHU-HOZEN"

BIRLA TYRES

COMPA N

IR K B LA
IES

AREA OF BUSINESS OF B.K. BIRLA GROUP OF COMPANIES

Group Worth: Rs. 45,000 million Employees : 40,000

5th TPM National Conference

OUT LINE OF OUR GROUP

TPM

Product
Chemicals

No. of Plants
6 1 2 1 5 1 1 1 1 1 1 4 1 2
Total 28

01 Cement 02 Heavy 12 11 01 12 06 12 14 10 14 12 01 05 04 05 05 08 09 05 07 02 03 13 03 MDF Board 04 Paper 05 Plantation 06 Polymerisation 07 Rayon 08 Refractories 09 Spun Pipe 01 01 10 Shipping 11 Tech. Institute 12 Textile 05 13 Tyre 14 Yarn TyreCord

01 01 03

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JH Step 1-4

HISTORY OF BIRLA TYRES

. STARTED COMMERCIAL PRODUCTION . TURNOVER 2003 - 2004 . EXPORT PERCENTAGE OF PRODUCTION . DISTRIBUTION NETWORK ALL OVER COUNTRY . ISO 9001 QUALITY MANAGEMENT SYSTEM . ISO 14000 ENVIRONMENT MANAGEMENT SYSTEM . QS 9000 QUALITY MANAGEMENT SYSTEM (SYSTEM FOR AUTOMOBILE INDUSTRY) . TPM EXCELLENCE AWARD FIRST CATEGORY . CERTIFICATION OF CALIBRATION LAB. BY NABL . OSHAS-18000 & SA-8000 CERTIFICATION MARCH92 Rs. 7893.31 MILLIONS 25 % 73 STOCK POINTS 1994 1998 1999 2000

TPM

2001 2004

JISHU-HOZEN PROCESS
1s SEIRI 2s SEITON Model Machine and Total Floor 3s SEISO

TPM

STEP#0
Preparation of Jishu Hozen Master Plan Selection of Model Machine Small Group Formation Preliminary Education and Training

STEP#1
Initial Cleaning Preparation of Fugai List

Audit

STEP#4
General Inspection Training on Modules, Nut & Bolts, Hydraulic, Transmission, Electrical & Pneumatics etc.

STEP#3
Preparation of Tentative standard for Cleaning, Lubrication and Inspection Horizontal application of Counter measures in other Machines

STEP#2
Countermeasure against Contamination Sources and Hard to access Areas

Audit

Audit

STEP#5
Standardisation of Checks Autonomous Inspection (Rev. of stamdards) Kaizen on hard to inspect area. Audit

STEP#6
Preparation of Jishu Hozen Calender for Machine

Audit

5th TPM National Conference

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JH Step 1-4

JISHU HOZEN STEP-1 (EXAMPLE)

Step - 1 : Initial Cleaning Example:
Before After

TPM

Dirty A-1 Passenger Tyre Curing Press.

Cleaned A1 Passenger Tyre Curing Press.

White tags are attached to abnormalities which can be taken care of by Operators.

Red tags are attached to abnormalities which can not be taken care of by Operators.

JISHU HOZEN STEP-2

PROCESS:
Analysis of Abnormalities detected during initial cleaning

TPM

Rectification of Abnormalities on Machine line, Loose Parts, Leakages, Un-necessary items, Missing parts etc.

Why why analysis of causes of forced deterioration ( Hard to access & Sources of Contamination

Countermeasure Plan for Hard to access areas and Sources of Contamination among group members (Optr., Prodn. I/c, Maint.I/c)

Implementation of Countermeasures and Visual Controls

Horizontal deployment plan for Countermeasures

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JH Step 1-4

EXAMPLE OF COUNTERMEASURE FOR CAUSE OF FORCED DETERIORATION

Phenemonen
Where What Why 1 Head Stock Solenoid hard to Sharp edges Assy. Solenoid Clean and Station Corners

TPM

Machine : TBM-M9 Analysis

Why 2 Why 3 Cause

Countermeasure
Countermeasure

In-Built design. Machine Dust & Dirt on Solenoid valve station Requirement Solenoid to be covered to prevent Valve & regulators. dust falling. Lack of lubrication Transparent cover to be and inspection. provided in place of metallic cover for easy inspection. Dust and dirt on Servicer Assy. Lack of Lubrication. Dust & Dirt. Tube light to be provided from both the sides. Oil level marking to be provided for easy inspection. Detachable cover with handle to be provided for easy handling.

Head Stock Main Motor gear Metallic cover To protect Assy. Solenoid box oil level and is there. main motor Station belt drive - hard and belt to inspect. from dust. Servicer Assembly. Head Stock Assembly. Head Stock Assembly. Hard to Inspect. FRL Unit. Less illumination. Hard to Inspect. Cover is fixed with bolts. Poor light arrangement. No oil level marking in Lubricator. Poor Design.

Motor base to clean

EXAMPLE OF COUNTERMEASURE AGAINST HARD TO CLEAN SUBJECT : SPLICE PRESS HOSE PIPE HARD TO CLEAN. BEFORE AFTER

TPM

CLEANING OF SPLICE PRESS HOSE PIPE DIFFICULT DUE TO FIXED COVER.

HINGED COVER PROVIDED. NOW EASY TO CLEAN

RESULT / BENEFIT :

EASY TO CLEAN. CLEANING TIME REDUCED FROM 25 MIN. PER WEEK TO 5 MIN. PER WEEK.

5th TPM National Conference

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JH Step 1-4

EXAMPLE OF COUNTERMEASURE AGAINST SOURCE OF CONTAMINATION SUBJECT : SOURCE OF CONTAMINATION BEFORE AFTER

TPM

FABRIC TOUCHING THE FLOOR AT BIAS CUTTER DANCER ROLL AND CONTAMINATES WITH DUST.

PLATFORM PROVIDED TO AVOID TOUCHING OF FABRIC WITH FLOOR. CONTAMINATION ELIMINATED.

RESULT / BENEFIT : REDUCTION OF QUALITY DEFECT. (FABRIC SCRAP

8 Kg. PER DAY SAVING OF Rs.800 PER DAY.

EXAMPLE OF VISUAL CONTROL SYSTEMS IMPLEMENTED FOR EASY INSPECTION

NOT OK

TPM

MILL TANK LUBE OIL PRESSURE INDICATOR

OK

MILL LUBE OIL PRESSURE INDICATOR

CHILLED WATER SPRAY INDICATOR

MILL LUBRICATION OIL INDICATOR

VALVE OPEN/CLOSE INDICATOR

5th TPM National Conference

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JH Step 1-4

JISHU HOZEN STEP-3

Finalisiation of Frq. (Daily, Weekly, Monthly) Group Members meeting to prepare tentative standard for Cleaning, Lubrication, Tightening, Inspection.

TPM

Finalisation of format and colour codes. Making lubrication points on machine, indicating type of lubrication and frq. Putting sticker on machine to show inspection points. Marking Route near machine Identifying points where visual controls are required.

Making the Points on Machine for Cleaning, Lubrication, Tightening and Inspection.

Making Visual Controls

Finalisiation of colour codes to be used for OK, Not OK, Open, Close etc.

Preparation of Monitoring Sheet for Record.

EXAMPLES OF COLOUR CODES, SYMBOLS FINALISED FOR VISUAL CONTROL AND JISHU HOZEN CHECKS

TPM

Green Colour for OPEN symbol. Red Colour for CLOSE symbol. Stands for Cleaning Activity. Stands for Lubrication Activity. Stands for Inspection Activity. Yellow Colour for daily check sheet. Pink Colour for Weekly check sheet.

5th TPM National Conference

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JH Step 1-4

TPM
EXAMPLE OF JISHU HOZEN CHECK RECORDS
CRITERIA : INSPECTION:
Route Ref. No. When SubAssembly Head Stock Where What Method 1 2 3 4 5 6 7 8

1 2 3 4 5 6

Daily

Disc Brake Unit (Oil leakage at fittings.)

No Oil Leakage

Daily

Bottom Stitcher Bead Stitcher

Bottom Stitcher Disc. Rotary encoder coupling alignment.

No play and jamming. No Mis-alignment.

Daily

Daily

Head Stock

Drum Collapsing.

Abnormal Sound..

Daily

Bead Stitcher Tail Stock

Bead tool air fittings ( Inside ), Lubricator oil Level.

No air leakage..

Daily

Oil upto specified mark.

(Signature)

JISHU HOZEN CHECK LIST (59J TYRE BUILDING M/C.)

DAILY
Route Ref. No. 1 When Criteria Sub-Assembly Where What How

TPM

INSPECTION
Time / Responsibility. 5 Secs. Operator Remarks

Daily Inspection

Bead Setter Assembly

Ply,Cup,Spring & bolt (Inside)

Looseness & Missing

Equipment Failure

Daily Inspection

Bottom Stitcher Bottom Stitcher Bead Setter Assembly Head Stock Assembly

Discs

Play,Jamming Gap Air Leakage

05 Secs. Operator 15 Secs. Operator 5 Secs. Operator 05 Secs. Operator

Equipment Failure and Quality Defect. Equipment Failure and Quality Defect.

Daily Inspection

Air Cylinder, Pipes,Joints

Daily Inspection

Ply,Cup,Spring Looseness & bolt (Outside) & Missing Main Motor & Blower.) Abnormal Sound.

Equipment Failure

Daily Inspection

Equipment Failure

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JH Step 1-4

PROCESS OF TRAINING

TPM

Objective and Curriculum for Operators

Skill Assessment

Preparation of Training Material and Facilities

Training Implementation

Evaluation Recording

Standard Basic

Objective Can set, adjust, run the machine correctly. Know Machine components and maintain them by practicing Jishu Hozen.

Training Topic Correct operation (Work instruction, Specification and Safety). Jishu Hozen Step - 1, 2 & 3 (Practice of Cleaning, Lubrication, Tightening and Inspection. Jishu Hozen Step-4 (GENERAL INSPECTION)

Advance

Can check machine by practicing Jishu Hozen.

Step - 4 : GENERAL INSPECTION

TPM

Establishment of General Inspection Category

Preparation of Training Material

Training Calender

Group Leader Training

Members Training

General Inspection Practice

Inspection Skill Assessment

Revision of Check Sheet

Audit

Next G.I. Category

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JH Step 1-4

Step - 4 : GENERAL INSPECTION

ESTABLISHMENT OF GENERAL INSPECTION CATEGORIES :
Area Categories Nuts & Bolts Lubrication Transmission Pneumatics Electrical Hydraulics Banbury 3 Roll, 4 Roll & Dip Extruders Bias Cutting & Band Building Bead Room Truck Tyre Bldg. Pass. Tyre Bldg. Tyre Curing Tube Section

TPM

X
Training Material

PREPARATION OF TRAINING MATERIAL (CATEGORY WISE) :

OPLS Categories Nuts & Bolts Lubrication Transmission Pneumatics Electrical Hydraulic MODLES / CUT SECTIONS MODLES FOR G.I. ITEMS

PERSONS INVOLVED: Training Department. Production Incharge. Maintenance Incharge.

6 4 12 15 8 12

10 12 14 23 13 6

Examples of TRAINING MATERIAL ON JH 4TH STEP

GENERAL INSPECTION AREA :- TRUCK TYRE BUILDING EQUIPMENT:- M.H.I. TYRE BUILDING MACHINE TRANSMISSION SYSTEM CATEGORY :(BEAD TOOL TRAVERSE MOVEMENT) MECHANISM G.I. PARTS G.I. ITEMS DAMAGED / WORN OUT KEY / KEY WAY DAMAGED GEAR TEETH GEAR OIL LEAKAGE

TPM

MOTOR SHAFT TRANSMISSION SYSTEM

BEAD TOOL TRAVERSE MOVEMENT

SPEED REDUCER

CHAIN & SPROCKET

ELECTRICAL CONTROL SYSTEM

LUBRICATION OF CHAIN LOOSENESS / TIGHTNESS OF CHAIN. SPROCKET ALIGNMENT SPROCKET KEY / KEYWAY / DAMAGE / WORN OUT.

LEAD SCREW AND FEED NUT

LEAD SCREW LUBRICATION LEAD SCREW & FEED NUT PLAY. BEAD TOOL ANGLE. (90 DEG.)

BEAD TOOL

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JH Step 1-4

Examples of TRAINING MATERIAL ON JH 4TH STEP

GENERAL INSPECTION AREA :- TRUCK TYRE BUILDING EQUIPMENT:- M.H.I. TYRE BUILDING MACHINE CATEGORY :TRANSMISSION SYSTEM (BEAD TOOL TRAVERSE MOVEMENT)

TPM

MOTOR SHAFT SPEED REDUCER CHAIN & SPROCKET LEAD SCREW AND FEED NUT BEAD TOOL

LEAD SCREW LUBRICATION LEAD SCREW & FEED NUT PLAY.

Examples of TRAINING MATERIAL ON JH 4TH STEP

G.I. PART:MACHINE :LEAD SCREW AND FEEDM.H.I. T.B.M. NUT CATEGORY :G.I. ITEM :TRANSMISSION LUBRICATION OF LEAD SCREW.

TPM

CHECKING METHOD WHAT TO DO

VISUALLY CHECK THAT LEAD SCREW IS NOT DRY OF LUBRICATION. IF LEAD SCREW IS DRY, LUBRICATE THE LEAD SCREW BY APPLYING GREASE.

WHY TO CHECK
LEAD SCREW NOT LUBRICATED LEAD SCREW AND FEED NUT WILL WEAR OUT. PLAY WILL DEVELOP.. BEAD TOOL WILL NOT REACH AT REQUIRED POSITION. QUALITY DEFECT WILL BE GENERATED

FEED NUT LIFE WILL BE REDUCED

MAINTENANCE COST WILL INCREASE.

5th TPM National Conference

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JH Step 1-4

INSPECTION SKILL ASSESSMENT

INSPECTION SKILL ASSESSMENT :TOPIC:- Knowledge and Maintenance of Pneumatic System. BASIC (REQUIRED LEVEL - 4) S. NO. Question 2606 K 1. Can you Identify The Pneumatic 1 Equipment . 2. What are the check point of FRL Unit. 1 3. What are the failures related to Pneumatic Cylinders in your area 4. What is a Celebration tag. 1 5. How to Identify out of calibration 1 Pneumatic Equipment. Score 4 K - KNOWLEDGE S - SKILL Each question carries one mark. CARD NUMBER 2546 2533 K S K S 1 1 1 1 1 1 1 1 1 1

TPM

S 1 1 1 1 1 5

2528 K S 1 1 1 1 1 1 1 1

2516 K S 1 1 1 1 1 1 5 1 1 1 1 5

2517 K S 1 1 1 1 1 1 5 1 1 1 1 4

1 1 5

1 1 4

INDIVIDUAL RECORD OF SKILL LEVEL T1

(SPIDER DIAGRAM) T2

1 - KNOWLEDGE AND SKILL BOTH UNSATISFACTORY. 2. -KNOWLEDGE SATISFACTORY. - 80% SCORE OF KNOWLEDGE 3. - SKILL SATISFACTORY. - 80% SCORE OF SKILL. 4 - KNOWLEDGE AND SKILL BOTH SATISFACTORY - 80% SCORE OF BOTH KNOWLEDGE AND SKILL.

T6

T3

T - TOPIC - EACH CO-CENTRIC CIRCLE LEVEL 0 TO 4. - YEAR WISE LEVEL INDICATED BY DIFFERENT COLOURED LINES. T5

T4

EFFECT OF STEP-4 TRAINING

NUMBER OF JH KAIZENS SUGGESTED BY OPERATOR = 133
TO STOP SPILLAGE LEAKAGE (OIL / POWDER) 96 FOR EASY WORKING 105 QUALITY WASTE CONTROL 45 13

TPM

SAFETY OTHERS 48 26

FREQUENCY PER MONTH

300 250 200 150 100 50 0

296

EQUIPMENT FAILURE DUE TO NO / POOR INSPECTION

CASES PER MONTH
25 20 15 10 5 0

QUALITY DEFECT DUE TO NO / POOR INSPECTION

24 18

122 44 0 STEP# 2 STEP# 3 STEP# 4

8 0 STEP# 2 STEP# 3 STEP# 4

STEP# 1

STEP# 1

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JH Step 1-4

TPM

5th TPM National Conference

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