Targets of JH

Targets of JH are...,

1. Improving the machine condition by bringing together the maintenance and production personnel and to see that the machine is restored to its original good condition and maintained in good condition thereafter.

2. Prevent the forced deterioration of the machine, develop the ability in the production personnel to carry out every day inspection, oiling, simple repairs & changing the worn out parts.
3. Improve the knowledge and skill level of the operator about the machine, How it works? What is the route cause of commonly occurring problems? How we can prevent them? Etc., Also it helps in finding out the abnormalities quickly and taking corrective actions over them.

Thus achieving Higher productivity, Zero Breakdowns in machines, giving Zero Defect Products and working in safe and ‘Zero Accident’ working condition are the targets of JH.

What is JH?

“I Own and I Operate” is the main principle in the TPM culture. Involvement of every operator, supervisor and the manager in keeping the machine condition and working condition in a good manner. This should be achieved with Kaizens and TPM circles. Since the technology upgrades continuously, the need for upgrading the operator also becomes equally important.

JH means Autonomous Maintenance i.e., maintaining one’s own machine by doing CLI RT effectively.

The alphabets in CLI RT means,

C – Cleaning
L – Lubrication
I - Inspection
RT- Retighten.

Following are the principles of JH.

a. Everybody maintains his own machine.
b. Thinking Process changes from ‘I operate, you maintain it” to ‘I operate, I maintain it’.
c. Operator should do able to Cleaning, oiling, Inspection and retightening on his own. Operator must not be dependant on the maintenance person, when he himself is capable of doing each one of the above pertaining to his own machine.
d. Only when the production machine changes (condition improves), we will notice change in our attitude and approach.

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.