Abnomality and jishu hozen
- 1. Learning While Implementing TPM Jishu Hozen Abnormality and Operations/ RVL/ TPM series TVS Motor Company
- 2. Learning while Implementing TPM Abnormality and Jishu Hozen Operations/ RVL/ TPM series 2 What is the purpose of “Jishu Hozen” or “Autonomous Maintenance”? For keeping the machine clean? To see that machine looks Spick and span? Maintenance 2S in work place? Creating a habit in operators to clean the machine? The answer is NO.
- 3. Learning while Implementing TPM Abnormality and Jishu Hozen Operations/ RVL/ TPM series 3 The idea behind implementing “Autonomous Maintenance” starts with a small but powerful word called Abnormality What is the purpose of “Autonomous maintenance”?
- 4. Learning while Implementing TPM Abnormality and Jishu Hozen Operations/ RVL/ TPM series 4 If we analyse why do we get defects the simple answer will be 1. We used defective incoming material 2. We used a method which is wrong or not sound 3. We used an equipment which is not capable 4. The people are not capable of operating or assembling properly.. Why do we have Customer complaints? If we try to find a common theme between this it can be stated in simple language: something is abnormal which we allow to escape from our factory to the customer.
- 5. Learning while Implementing TPM Abnormality and Jishu Hozen Operations/ RVL/ TPM series 5 Why do we have Customer complaints? Extending this thought positively we can say the only way of making customer complaints zero is to 1. Capture the abnormality before it reaches the customer 2. Eliminate it from the root.
- 6. Learning while Implementing TPM Abnormality and Jishu Hozen Operations/ RVL/ TPM series 6 Same is the case with Breakdowns and accident… Does breakdown happens suddenly? Normally the answer will be “Yes”! In reality we can see breakdown coming if we understand something is “abnormal”.We allow abnormalities to exist in the factory which create breakdowns and accidents. As we said earlier breakdowns can be made zero if we 1. Capture the abnormality before before it gets converted in to breakdowns 2. Eliminate it from the root.
- 7. Learning while Implementing TPM Abnormality and Jishu Hozen Operations/ RVL/ TPM series 7 Capturing Abnormalities…. It is easy to say that we should capture abnormality, but difficult to do. This is because to capture the abnormality we must understand the difference between what is normal and what is abnormal.
- 8. Learning while Implementing TPM Abnormality and Jishu Hozen Operations/ RVL/ TPM series 8 What is “Abnormal”? Dirty machine is abnormal Broken glass of the door is abnormal Loose wires is an abnormality Leakage through pipes is abnormal Chips flying on the floor from machine is abnormality Coolant spillage is abnormality Loose bolts is abnormality Spindle getting very hot is abnormal Scratch marks on the parts is abnormal Loading component wrongly is abnormal The list is endless.. Can we list some abnormalities? Easy job.
- 9. Learning while Implementing TPM Abnormality and Jishu Hozen Operations/ RVL/ TPM series 9 Is there something common in these situations which can help in defining what is abnormal? Something which is deviating from standard is an abnormality This is a good theme to start with. But there is still a small catch in it. What is the standard? The standard may vary from person to person.
- 10. Learning while Implementing TPM Abnormality and Jishu Hozen Operations/ RVL/ TPM series 10 Let us take one example.. Second person may say out of 4 mounting screws 1 is missing. That is why it is vibrating. So missing bolt is abnormality Looking at the coolant motor One person says “ the motor is vibrating. This is an abnormality” The third person may say : The motor is not vibrating, but out of 4 mounting bolts I can see in one case the spring washer is missing an that can cause vibration tomorrow.
- 11. Learning while Implementing TPM Abnormality and Jishu Hozen Operations/ RVL/ TPM series 11 Let us take one example.. Look at these observations. What do they suggest ? They suggest that the capability of identifying abnormality varies from person to person. If we raise the standard for defining abnormality you can find more!! The first person may find 100 abnormalities The second may find thousand and the third may find 10000 abnormalities!!
- 12. Learning while Implementing TPM Abnormality and Jishu Hozen Operations/ RVL/ TPM series 12 Levels of abnormalities. This can be compared with the doctor’s check ups. First he does general check up To find out abnormalities If that is not helping he Does a thorough check up with some tests If still the problem is not sorted out He recommends CT scam etc.
- 13. Learning while Implementing TPM Abnormality and Jishu Hozen Operations/ RVL/ TPM series 13 We call these levels as 1. Site seeing level, 2. Housekeeping level and 3. microscopic level. Site seeing House keeping Microscopic Base level High level Benchmarking level Levels of abnormalities.
- 14. Learning while Implementing TPM Abnormality and Jishu Hozen Operations/ RVL/ TPM series 14 Autonomous maintenance is an excellent tool improve the capability of a person from Site seeing level to Microscopic level If we make a person capable of identifying a minute defect we can make sure that no defect will be passed on to the customer No abnormality will get converted in to breakdown or accident.
- 15. Learning while Implementing TPM Abnormality and Jishu Hozen Operations/ RVL/ TPM series 15 This concept can be further explained By the ice burg theory… Defects, Breakdowns Accidents Abnormalities Depth of Investigation Dirt, Dust, leakages, Broken parts, unwanted parts 1. As the theory suggests, the tip of the Ice burg is always visible. It is important to find out the portion hidden in the sea. This is done effectively only if you have the depth or “Capability to identify high level abnormalities 2. It is also essential to identify the smaller ice burgs which are potential causes to create a big ice burg Potential causes
- 16. Learning while Implementing TPM Abnormality and Jishu Hozen Operations/ RVL/ TPM series 16 Jishu Hozen is the telescope…. Jishu hozen gives a telescope in the hands of operators in the form of “Capability” to identify minute abnormalities and creates a culture of even finding smaller ice burgs. Breakdowns, Scrap Line stoppers accidents Dirt, Dust Coolant spillage Leakages, Broken parts, Chips flying, accumulated unwanted parts Loose parts Unsafe Conditions Difficult to do.. Non adherence Unsafe acts Abnormalities Depth of Investigation Potential causes Capability
- 17. Learning while Implementing TPM Abnormality and Jishu Hozen Operations/ RVL/ TPM series 17 Autonomous Maintenance aims at improving capability of operator for Judging the abnormality Implementation of corrective measures Fix higher and higher standards of what is acceptable & what is not acceptable Follow the rules in letter & sprit once decided
- 18. Learning while Implementing TPM Abnormality and Jishu Hozen Operations/ RVL/ TPM series 18 With this background now look at “Autonomous Maintenance” and you might find entirely different picture 1.Initial Cleaning 2.Counter measures against source 3.Prepare standards for cleaning & Oiling 4.General Inspection 5.Autonomous Inspection 6. Standardisation 7.Autonomous Management
- 19. Learning while Implementing TPM Abnormality and Jishu Hozen Operations/ RVL/ TPM series 19 Seven steps… Step 1,2 and 3 encourage people to develop this microscopic eye for abnormality. This effectively brings back the machine to it’s ‘Basic condition.’** and the condition is maintain as people start noticing minute abnormalities immediately So the machines change along with people. **In the gamba review of plant 1 a question was asked to Mihara san “what is basic condition” He immediately cleaned a guard on the machine and said this is the basic condition!! Basic Condition Deterioration
- 20. Learning while Implementing TPM Abnormality and Jishu Hozen Operations/ RVL/ TPM series 20 Seven steps… Step 4 and 5 will provide inputs for operators which will improve his capability further once he knows 1. The importance and functions of various systems of any equipment 2. The relationship between the machine and quality Step 6 and 7 will improve capability of people for having a global view of his work place and even eliminate invisible abnormalities like non-adherence to system and procedures
- 21. Learning while Implementing TPM Abnormality and Jishu Hozen Operations/ RVL/ TPM series 21 Change Culture Summrising.. JH Creates vital enthusiastic work environment Change Equipment Change Attitude Change Workplace CapabilityCan we Summrise by saying it will change the work culture And this work culture change will happen by “DOING” rather than a lecture on how to change….
- 22. Learning while Implementing TPM Abnormality and Jishu Hozen Operations/ RVL/ TPM series 22 Practical example A practical example of what happened to the tag status in Plant 2 is shown here.The abnormalities found last year were at the level of 4000. In first 7 months Plant 2 has found out over 33000 abnormalities Site seeing House keeping Microscopic 4502 1620.0 460.0 33839 11512 26249 8377 0 5000 10000 15000 20000 25000 30000 35000 '04- 05 Apr Jun Aug OCT DEC FEB Abnormalities identified Abnormalities corrected
- 23. Learning while Implementing TPM Abnormality and Jishu Hozen Operations/ RVL/ TPM series 23 JH is the “Power” What is the role of other pillars and JH? JH is the power and other pillars are enablers. To start with all other pillars must support JH activity and make it strong. A strong JH team means thousand of eyes and ears and noses ( five senses) expert in identifying minute abnormality) Once JH becomes strong it will support all other pillars for achieving their objective.
- 24. Learning while Implementing TPM Abnormality and Jishu Hozen Operations/ RVL/ TPM series 24 JH is the “Power” Unless and until we have the strong base of JH no improvement by any other pillar will sustain. We may start doing excellent technical innovations, improvements fool proofing projects but if we do not have capable people to handle them these improvements will not sustain. If pokayoke are done we also install a pokayoke checklist for audit. If the operator is having strong eye for abnormality he will not allow the machine to run when pokayoke is not working. The there is no need of any pokayoke audit.. QM pillar can focus on further improvements than spending energy on sustenance
- 25. Learning while Implementing TPM Abnormality and Jishu Hozen Operations/ RVL/ TPM series 25 JH is the “Power” This character in Chinese means “People” In the initial stage the people from other pillars should support JH. If it is not done JH will collapse JH Other Pillars JH Other Pillars Once JH becomes strong it supports all other pillars especially QM & PM to eliminate defects & breakdowns
- 26. Learning while Implementing TPM Abnormality and Jishu Hozen Operations/ RVL/ TPM series 26 Let us ask the question again now What is the purpose of “Autonomous maintenance”? For keeping the machine clean as any dirty part is an abnormality To see that machine looks Spick and span as it will maintain its basic condition by eliminating abnormalities Maintenance 2S in work place because any thing unwanted or not in place is also an abnormality Creating a habit in operators to clean the machine as he understands “cleaning is inspection” and it gives a chance to find out minute abnormalities causing breakdown, defect or accident
- 27. Learning while Implementing TPM Abnormality and Jishu Hozen Operations/ RVL/ TPM series 27 Just do it..