Seven types of Abnormalities

1. Minor Flaws
2.Unfulfilled Basic Conditions
3. Inaccessible Places
4. Contamination Sources
5. Quality Defect Sources
6. Unnecessary and Non-urgent items
7. Unsafe Places

JISHU HOZEN STEP- 3

•Step 3: Creation and maintenance of(Provisional) Standards for Cleaning and Lubrication.

•Group members should set their own standards.
- People doing the cleaning and lubrication need to understand the vital importance of the tasks - The equipment must be improved to facilitate cleaning and lubrication
- The time required for cleaning and lubrication must be an official part of daily schedule.

•Key points for creating Lubrication standards :

–Clearly specify the lubricant to be used, and unify types whenever possible to reduce variety and promote consistency
–Thoroughly list all lubrication inlets and other sites. In centrally lubricated equipment,improve the lubrication system and diagram it showing the route from pump to main pipes,branch valves,branch pipes,and lubrication points.
–Check for blockage in branch valves and differences in branched volumes, and find out if lubricant is reaching all lubrication points.
–Measure the lubricant consumption rate(during one day or a week)
–Measure the amount used per application.
–Measure the pipe lengths(specially grease pipes) to see for example, if two pipes may be needed instead of one
–Review the disposal method for dirty lubricant (after greasing)
–Create lubrication labels and attach them to all lubrication points
–Establish a service station(for maintenance of all lubricants and lubrication equipment)
–List all difficulties concerning lubrication
–Work out the division of lubrication-related responsibilities with maintenance department.

JISHU HOZEN STEP-2

Step 2: Eliminate sources of contamination
and inaccessible areas
•AIM - Equipment
-Make it an equipment in which elimination of forced deterioration based on fouling mentioned in step 1 is maintained in a short period
-Make it into an equipment for which visual control can be accomplished(Abnormal condition can be easily recognized)
Fix sources of Contamination
Improve areas that are inaccessible for cleaning and inspection
Emphasize joy of making improvements

Summary of improvement points:

–Make equipment easier to clean
–minimize spread of dirt,dust and grime
–Stop contamination at source
–Minimize scattering of cutting,oil and cutting debris
–Speed up flow of cutting oil to prevent accumulation of cutting debris
–Minimize area through cutting oil flows
–Make the equipment easier to inspect
–Install inspection windows in the equipment
–Tighten loose areas in the equipment
–Eliminate the need for oil pans
–Install more oil gauges
–change the location of lubrication outlets
–Rationalize wiring layout
–Change the piping layout
–Make it easier top replace equipment parts

Step 1 – Initial cleaning

•All- around clean-up of dust and dirt on equipment.
•Finding and restoration of “Fuguai” (abnormalities)
•Oiling and re-tightening of bolts and nuts

Abnormalities :

•Any deviation from the original condition of the equipment which deteriorates machine performance

Example of Abnormalities
•Loose bolts & nuts
•Loose wires
•Missing parts
•Rusted parts
•Broken parts
•Cracked parts
•Air leaks
•Oil leaks
•Coolant leaks
•Dirt, dust and cobwebs
•Oil on the floor
•Scrap around the machine
•Burr and swarf around the machine
•Abnormal heat
•Abnormal sound
•Abnormal vibration

JISHU HOZEN-Step 1

•AIM

The Equipment
- Prevent forced deterioration based on dust and fouling.
- Hidden defects will come to the surface.

Personnel:
-Touch the equipment and develop affection towards the equipment and take interest in it.
-Development of eyes that will detect the fuguai portion of the equipment.
-Learn the function and structure of the equipment parts.
-Know the weak points of the equipment.

Autonomous Maintenance

•BASIC CONCEPT
–If all personnel who are engaged in the equipment operation can change their basic concept and behavior, the stoppage or deterioration of equipment functions could be prevented and “Zero Failures and Defects” could be achieved.
–If equipment is changed, the workers will change.If the workers change, the production field can be changed
–Self fulfillment should be realized through employment of a step-by-step
system to positively promote the development,with all workers participating in the activities under the organization led small groups.

DEFINITION
The purpose of Autonomous maintenance is to teach equipment operators how to maintain their equipment by performing daily checks, lubrication, replacement of parts,repairs, precision checks, and other maintenance tasks, including the early detection of abnormalities

Purpose:
Training of operators proficient in equipment
Protecting one’s own equipment by one’s staff
Members: Operator, Line Leader
•Activities:
•Implementation of 7 steps
•1.Initial clean-up
•2.Countermeasures for the source of problems and measures for difficult-to-access locations.
•3.Creation of tentative autonomous maintenance standards.
•4.General inspection.
•5.Autonomous inspection.
•6.Standardization.
•7.All-out goals management.