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Autonomous Maintenance (Jishu Hozen)

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About the Program

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Failure

Natural Deterioration Forced Deterioration

Extend Lifetime Eliminate Causes

Corrective maintenance Establishment for


basic condition
Prevent errors by improving operability Cleaning
Improve maintainability and repair quality Lubricating
Improve safety and reliability Inspection
Tightening

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Why Abnormalities are to be removed from the
equipment ?

Abnormalities leads to

Forced Deterioration Leads to

Breakdown Defects Accidents

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Principles of Jishu - Hozen
Principal of Autonomous Maintenance

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Basic Concept

Initial Cleaning Abnormalities, Inaccessibility for cleaning,


(Inspection) Lubrication, Inspection and tightening.

Countermeasure Removal of abnormality,


arrest the source of contamination
Kaizens

Evaluation

Standardization

Horizontal
Deployment
Further
Improvement

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Steps of Jishu - Hozen
Total Steps

Step 0 – Thorough Cleaning


Step 1 – initial Cleaning and tagging
Step 2 – Implementing Countermeasures
Step 3 – tentative standards for CLIT and PM

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STEP 0 – THOROUGH CLEANING

Understand function of equipment and auxiliaries.


Identify Failures / Breakdowns Old history or records)
Make the list of –
Hard to clean areas
Hard to lubricate
Hard to inspect
Hard to tighten
Hard to adjust
Areas to visualize
Putting red tags
Putting white tags
Visual sheet for using cleaning tools

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STEP 1- INITIAL CLEANING AND IDENTIFICATION OF
ABNORMALITIES

Cleaning with meaning


Cleaning for no cleaning
Inspection means finding problems
Identification of abnormalities

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Importance of Why – Why Analysis

Why –Why Analysis

To Understand the cause of the abnormalities

Leads to
Better Understanding and prevent the
same in future
Leads to

To restore and sustain the


basic condition

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STEP 2- COUNTER MEASURE OR SOURCE OF PROBLEMS AND
DIFF. LOCATION

 By Kaizens
 By One point lessons

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STEP 3

FORMULATION OF LUBRICATION AND CLEAN UP STANDARDS

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HOW TO IMPLEMENT AM ON THE SHOP FLOOR ?

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Target Model machine – My machine Campaign

S A B C
Safety and
Environmental pollution Failure would cause Failure would cause Failure would cause and
major accident resulting minor accident not impact on safety and
in mandays loss and resulting in mandays environment problems in
plan shutdown. loss and plan shutdown. surrounding area.

Q Failure would cause Failure would cause Failure would cause No


Quality and yield defective components defective components rejection and No rework
where can not be where can be reworked would occur.
reworked.

W Two Shift Operation One Shift Operation Intermittent operation


Working Status
D Failure would shut down Failure would shut down Stand by unit available
Delay Factor entire plant area. relevant system

P Frequent stops Occasional stops Hardly Any stops


Period (Failure Interval)

M Repair Time 4 hours or Repair time 1 – 4 hours Repair time less than 1
Maintainability more hour.

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Basis of A B C ranking – Truth table
S Q W D P M Status
A X X X X X A
X A X X X X A
B/C B/C A/B A A A A
B/C B/C C C A/B A/B B
B/C B/C C C X X C
B/C B/C C A/B C X C
B/C B/C C A/B A/B C C
B/C B/C A/B B/C A/B C C
B/C B/C A/B B/C A/B A/B B
B/C B/C A/B B/C A/B A/B B
B/C B/C A/B A B/C C C
B/C B/C A/B A B/C A/B B
B/C B/C A/B A A B/C B
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7 Types of Flaws

1. Minor Flaws
2. Unfulfilled basic conditions
3. Inaccessible places
4. Contamination Sources
5. Quality defect source
6. Unnecessary and non – urgent items
7. Unsafe places

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1. Minor flaws

Contaminatio Dust, dirt, powder, oil, grease rust and paint


n
Damage Cracking, crushing, deformation, chipping,
bending.
Play Shaking, falling out, tilting, eccentricity,
wear, distortion, corrosion.
Slackness Belts, chains

Abnormal Unusual noise, overheating, vibration ,


phenomenon strange smells, discoloration, incorrect
pressure or current.
Adhesion Blocking, hardening, accumulation of
debris, peeling, malfunction.
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2. Unfulfilled basic condition
Contaminatio Dust, dirt, powder, oil, grease rust and
n paint
Damage Cracking, crushing, deformation, chipping,
bending.
Play Shaking, falling out, tilting, eccentricity,
wear, distortion, corrosion.
Slackness Belts, chains

Abnormal Unusual noise, overheating, vibration ,


phenomenon strange smells, discoloration, incorrect
pressure or current.
Adhesion Blocking, hardening, accumulation of
debris, peeling, malfunction.
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3. Inaccessible Places –
Hard to Access

Cleaning Machine construction, Covers, layout,


Footholds, Space
Checking Machine construction, Covers, layout,
Footholds, Instrument position and orientation,
Operating – Range display.
Lubrication Position of lubricant inlet, construction, height,
footholds, lubricant outlet, space.
Tightening Covers, Construction, Layout size, Space

Operation Machine layout, Position of valves, Switches


and levers, Footholds.
Adjustments Position of pressure gauges, Thermometers,
Flow meters, Moisture gauges, Vacuum .
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4. Contamination Sources
Product Leaks, spills, spurts, scattering, Overflow

Raw Material Leaks, spills, spurts, scattering, Overflow

Lubricants Leaking, spills, seeping oils, hydraulic fluids,


Fuel Oil,
Gases Leaking compressed air, gases, steam,
vapors, exhaust fumes.
Liquids Leaking water, waste water, leaking supply
lines.
Scrap Flashes, cuttings, packaging and non –
confirming products (Contamination by people
and forklifts, cracked walls and windows.)
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5. Quality Defect Source

Foreign Dust, rust , powder, chips, moisture, wire


Matter scraps, wood pieces, paper pieces, stones
Shock Dropping, jolting, collision, Vibration.

Moisture Too little or too much, Infiltration.

Grain Size Abnormalities in screens, compressed air


separators,
Concentratio Inadequate warming, Heating,
n Compounding, Mixing, Evaporation,
Stirring Etc.
Viscosity Inadequate warming, Heating,
Compounding, Mixing, Evaporation,
Stirring Etc.
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6. Unnecessary and
Non – urgent Items
Machinery Pumps, Fans, Compressors, Columns,
Tanks Etc.
Piping Pipes, Hoses, Ducts, Valves, Dampers Etc.
Equipment
Measuring Temperatures, Pressure gauges, Vacuum
Instruments gauges, Ammeters Etc.
Electrical Wiring, Piping, Power Leads, Switches ,
Equipment Plugs Etc.
Jigs, Fixtures General Tools, Cutting Tools, Jigs, Molds,
and Tools Dies and Frames.
Spare Parts Stand by equipment, Spares, Permanent
Stocks, Auxiliary Materials.
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7. Unsafe Places
Floors Unevenness, Ramps, Projections,
Cracking, Peeling, Wear etc.
Steps Too Steep, Irregular, Peeling anti – slip
covering, Corrosion, Missing Handrails Etc

Lights Dim, Out of Positin, Dirty or broken covers,


No safety or emergency stop devices.
Rotating Displaced, Fallen off or broken covers, No
machinery safety or emergency stop devices.
Lifting gear Wires, Hooks, Brakes and other parts of
the crane.
Other Special substances, solvent, Toxic gases,
Insulating Material, Danger sign, Protective
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Next Step of the training program

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Next Presentation on Jishu - Hozen

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