TPM QM Training

TPM Club India Quality Maintenance Pillar
PILLAR
Hinshitsu Hozen
or
Quality Maintenance
1
Confederation of Indian Industry
Hinshitsu-Hozen
What is Hinshitsu-Hozen?
To maintain integrity of quality (state of 100% non-defectives)
* Condition setting :
Set conditions for zero defects aimed at equipment and processes that do
not produce quality defects.
* Daily and periodical inspections :
Inspect and measure conditions in time series.
* Quality preventive maintenance :
Prevent quality defects by maintaining measured values within the standard
* Trend control and predictive maintenance :
Predict possibilities of quality defects occurring by observing trends of
measured values.
* Prior countermeasures:
Take measures beforehand
JIPM, 1994 2
Hinshitsu Hozen Concept

Quality Defect Factors
Caused by raw material Caused by equipment Caused by method Caused by conditions of
conditions precision conditions people involved
Procuring/Producing Manufacturing equipment Devising methods not to Fostering operators

materials not to generate not to generate defect generate defects proficient in equipment
defects and job
Quality Assurance
Jishu-Hozen activities
+
+
Equipment and Design check Material Skill Education and Training
environment management Management
PM Pursue relationship between quality Maintenance and

Analysis characteristics and material and energy management ability training
condition / equipment precision / method (Ability to find cause system
conditions
troubles and to quickly and
correctly take actions)
Set conditions of equipment not to
generate defects
Management of conditions not to generate

defects
(Hinshitsu Hozen) Zero quality defects JIPM, 1987 3

Implementation Procedure for

Quality Maintenance
Understanding quality defect phenomena.
Prepare QA Matrix.
Set 4M conditions.
Identify Process Point.
Conduct PM Analyses.
Identify Q-components
Prepare QM Matrix.
4
QM Master plan
Master Plan for quality maintenance is planning of various
activities in this pillar with respect to the time frame in
months and years. According to the stage of TPM
implementation it can start at various levels. In the
beginning it will start with data collection on defects to
improving conditions to sustaining zero defect conditions.
5
TPM Club India
TPM Steps for QM-Pillar Quality Maintenance Pillar
Step-1 : Understanding the Defect

-Q Characteristics
-Defect Characteristics
-Defect Mode
-Defect Phenomenon.
-Data Collection.
Step-2: QA Matrix
-Defect Mapping
-Defect Characteristics Vs Sub process
-Defect Mode Vs Support Process.
Step-3: Analyse 4M conditions.

-Prepare draft of 4M conditions.
-Status of 4M conditions.
-Survey of 4M conditions.
-Identify the gaps in 4M conditions.
Step-4,5 & 6: Problem countermeasure and restoration.

-Why-Why Analyses .
-Quality improvements through Kaizens.
-PM Analyses.
Step-7,8 & 9:
-Component Function
-Identify Process Point.
-Identify Q-components.
Step-10: QM Matrix
6
Defects classification
A - Type defect B - Type defect C - Type defect
OK OK NOT OK
NOT OK NOT OK
Action No action Action

taken by OK
by operator taken by
operator operator
LSL OK USL OK
LSL USL OK
LSL USL
The output is (OK) initially The output is (OK) initially

Becomes (NG) Becomes (NG) The output is (NG) initially
Corrective action is taken No action taken by Action taken by operator
by operator operator Becomes (OK)
Becomes (OK) Becomes (OK) (setting scrap)-Why-Why
Uue Why Why Analysis Use PM Analysis 7
Understanding Defect Phenomenon
Defect Phenomenon is defining the defect characteristics in the form of defect mode.
Phenomenon can be defined in 5W & 1H style (means What, Where, When, Which,
Who, How much)
1. Quality Characteristics (From Customer or for customer). For e.g. Smooth Shifting of gears.
2. Defect Characteristics (Not achievement). E.g.-Shifting not ok/Shifting Bad.
3. Defect Mode (Modes of defect Characteristics). E.g- Shifting hard, shifting loose.
8
Drafting of QA (Quality Assurance) matrix and

reflection in standards
QA Matrix is prepared to establish the relationship between
defect / defect mode and the process which causes it. It
requires data collection for defects at various process
stages to prepare a QA Matrix.
9
QA Matrix
Quality Characteristics-Proper tightening of bolt
Defect Characteristics- Improper tightening
Defect Modes
Quality
Support
Process Sub-Process Index
Process
(Process)
Mode-2 Mode-4
Mode-1 Mode-3
Excess Washer
Bolt loose Bolt broken
Tightening flared
Rear Wheel
Nut Runner Air-Pressure 4
Fitment
Tightening
4
speed
Torque wrench Torque value 4
Bolt Bolt size X X 2
Washer Washer Size X X X 1

Quality Index (Defect) 4 3 4 4 15
10
11
Why-Why Analyses Sheet-Defect

Product Date Time:
Machine M/c No.
Defect
Previous Occurance
Phenomenon
Why Due to Date:

Effectiveness (Why Not
Why 1 OK)
Why 2 Counter measures Details
Why 3
Why 4
Why 5
Root Cause

Root Cause Due to Tick Root Cause (Due to) Tick Particulars
1. Poor Basic condition Man Kaizen Idea No.
2. Poor Operating
condition Machine OPL No.
3. Deterioation Material PM Calender
4. Weak Design Method Jishu Hozen
5. Poor Skill Horizontal Deployment Possible Yes/No
Prepared by
Department Head
12
Component function Analyses
Machine-Systems-Assemblies-Components
Actual Failure is Component failure not the machine.
Defect-Component malfunction-Component failure.
Part Problem/Defect Extent of function Inspection period

Function
Name Caused degradation specified/actual

13
Process Point Analyses Report
14
Quality Component
15
QM Matrix: To relate the malfunction of component (abnormality ) with defect mode.
16

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TPM Club India Quality Maintenance Pillar

To maintain integrity of quality (state of 100% non-defectives)

Hinshitsu Hozen Concept

Procuring/Producing Manufacturing equipment Devising methods not to Fostering operators

PM Pursue relationship between quality Maintenance and

Management of conditions not to generate

(Hinshitsu Hozen) Zero quality defects JIPM, 1987 3

Implementation Procedure for

Identify Process Point.

Master Plan for quality maintenance is planning of various

activities in this pillar with respect to the time frame in

months and years. According to the stage of TPM

implementation it can start at various levels. In the

beginning it will start with data collection on defects to

improving conditions to sustaining zero defect conditions.

Step-1 : Understanding the Defect

Step-3: Analyse 4M conditions.

Step-4,5 & 6: Problem countermeasure and restoration.

Action No action Action

The output is (OK) initially The output is (OK) initially

Understanding Defect Phenomenon

2. Defect Characteristics (Not achievement). E.g.-Shifting not ok/Shifting Bad.

Drafting of QA (Quality Assurance) matrix and

QA Matrix is prepared to establish the relationship between

defect / defect mode and the process which causes it. It

requires data collection for defects at various process

stages to prepare a QA Matrix.

Why-Why Analyses Sheet-Defect

Why Due to Date:

Component function Analyses

Actual Failure is Component failure not the machine.

Defect-Component malfunction-Component failure.

Part Problem/Defect Extent of function Inspection period

Process Point Analyses Report

QM Matrix: To relate the malfunction of component (abnormality ) with defect mode.

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