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Autonomous Maintenance

Dr. Hajime Yamashina Professor Emeritus, Kyoto University Member of RSA (U.K.) Member of Royal Swedish Academy of Engineering Sciences (Sweden)

1

Autonomous Maintenance 1. 2. 3. 4. 5.

Introduction Expected Abilities of Operators Promote AM Step by Step Autonomous Maintenance Audit Criteria and the Check List of Autonomous M aintenance 6. Three Key Points for Successful Small Group Acti vities 7. Roles of Operators and Maintenance People Appendix : Examples of One Point Lessons

1. Introduction A machine breakdown does not occur suddenly. There is a symptom of the breakdown before it takes place. That is, it is the result of the growth of a minor defect. •

To eliminate breakdowns, it is necessary to check equipment for detecting a symptom of a breakdown. •

Maintenance crew cannot detect and cover all the symptoms of breakdown. •

It is the operators of machines and processes who can catch the information on the status quo of an item of plant and prevent it from breaking down. •

1

Unless the operators know how to maintain equipment, they cannot help having equipment breakdowns. •

AM is powerful in case where there are operators and where breakdowns, defectives and minor stoppages take place due to lack of maintaining the basic condition of equipment and when they inspect their equipment. •

1

4

In general, one third of breakdown comes from lack of basic conditions.

Total number of breakdowns

•

PM Including Human errors PM(AM)

Lack of the basic conditions

Another one third of them can be avoided if the competence of AM people can be raised and AM step 1 – step 7 are carried out rigorously with well organized inspection of natural deterioration, but this costs much money. •

The rest can be tackled by PM step 1 – step 3. Once we establish a PM calendar, we understand what we have to do with the equipment. •

5

2. Expected Abilities of Operators 2.1 Abilities to Understand Process Performance and Functions and Operate Process Correctly 2.2 Abilities to Understand Properties of Materials Be ing Handled and Perform Correct Adjustment and Setti ng 2.3 Abilities to Detect Abnormalities Promptly and Tak e Emergency Action Against Abnormalities 2.4 Abilities to Recognize Signs of Abnormality, Deal with Abnormalities Correctly and Perform Periodic Over haul Checking and Parts Replacement Correctly 2.5 Four Steps Capable Operators

Abilities to Understand Process Performance and Functions and Operate Process Correctly It's easy to see results.

Devel op an ey e f or sl i ght abnor mal i t i es

What do we have her e, a little f l aw?

Al l cl eaned and oi l ed!

Br e a k d o wn s

Pr o d u c De f e c t s t i vi t y

Ever yt hi ng’ s i n per f ect wor ki ng condi t i on t oday!

Anot her day wi t h no br eakdowns and no def ect s!

Thi nk syst emat i cal l y! • Act syst emat i cal l y! •

Abi l i t i es

t o Under st and Pr oper t i es of Mat er i al s Bei ng Handl ed and Per f or m Cor r ect Adj ust ment and Set t i ng

I t must be a l oose bol t t hat ’ s causi ng t he vi br at i on.

No, you’ r e wr ong! Ther e’ s a wor n bear i ng you shoul d check!

The vibration ofthe m otor is too big !

the vibration ofthe m otor occurred because of loose nuts.

Abi l i t i es t o Det ect Abnor mal i t i es Pr ompt l y and Take Emer gency Act i on Agai nst Abnor mal i t i es I can sense abnorm ality ! No, according to m y experience, it's norm al! check point check point

check point

abnorm al

norm al

Abilities to Recognize Signs of Abnormality, Deal with Abnormalities Corr ectly and Perform Periodic Overhaul Checking and Parts Replacement Co rrectly

Four Steps Capable Operators

4. r ecogni zes si gns of abnor mal i t y, deal wi t h abnor mal i t i es cor r ect l y and per f or m per i odi c over haul checki ng and par t s r epl acement cor r ect l y

3. det ect s abnor mal i t i es pr ompt l y and t ake emer gency act i on agai nst abnor mal i t i es 2. under st ands pr oper t i es of mat er i al s bei ng handl ed and per f or m cor r ect adj ust ment and set t i ng 1. Under st ands pr ocess per f or mance and f unct i ons and oper at e pr ocess cor r ect l y

Step 1: The operator can detect problems and understan d the principles and the procedures of equipment impr ovement.

Don' t

Make

t he

l et

t he machi ne di r t y.

get

machi ne i n such a way be easi l y checked.

as

to

St ep 2: The

oper at or st r uct ur e

Structural diagram

knows t he f unct i on of equi pment . Real l y know t he f unct i ons and st r uct ur e of your equi pment .

and

Step 3: The operator knows the relationship between equipm ent accuracy and product quality.

Step 4: The operator can repair equipment.

Mastering of Basic Skills Proper bolting

Centering of pooleys and gears

Exchange of bearings

Prevention of oilleakage

３３ Promote AM Step by Step 3.1 The Seven Steps of AM 3.2 The Four Steps to Capable Operators and the Seven Steps of AM 3.3 Developing an Autonomous Maintenance Program 3.4 The Goals of AM

The Seven Steps of AM Step 7 Step 6 Step 5

Workplace organization Autonomous and inspection housekeeping

Step 4 General inspection

Step 3

Challenge this step and find benefits.

Tentative standards

Step 2

p1

Fully implemented autonomous management

Countermeasures against sources

Initial cleaning

Reactive

Preventive

21

Proactive

Promote autonomous maintenance step by step Step

1.

2.

Perform Initial cleaning Address contamination sources and inaccessible places

Activities • Eliminate dust ant dirt from main body of equipment • Expose irregularities such as slight defects, contamination sources, inaccessible places, and sources of quality defects • Eliminate unnecessary and seldom-used items, and simplify equipment •

Reduce housekeeping time by eliminating sources of dust and dirt, preventing scatter, and improving parts that are hard to clean, check, lubricate, tighten, or manipulate

Formulate work standards that help maintain cleaning, lubricating, and tightening levels within minimal time and effort • Improve the efficiency of checking work introducing visual controls •

3.

Establish leaning and checking standards

Provide inspection skills training based on inspection manuals • Get individual equipment items into peak condition by subjecting them to general inspection • Modify equipment to facilitate checking. Make extensive use of visual controls 22 •

4.

Conduct general equipment inspection

Step

Activities

5. Perform general process inspection

• Provide instruction in process performance, operation, and adjustment and in methods of handing abnormalities in order to improve operational reliability by developing process-competent operators • Prevent inspection duplications and omissions by incorporating provisional cleaning and inspection standards for individual equipment items into periodic inspection and replacement standards for entire processes or areas

6. Systematize autonomous maintenance

• Achieve quality maintenance and safety by establishing clear procedures and standards for dependable autonomous maintenance • Improve setup procedures and reduce work-in-process • Establish a system of self-management for work place flow, spares, tools, work-in-process, final products, data, etc.

7. Practice full selfmanagement

• Evolve activities and standardize improvements in line with company and plant policies and objectives, and reduce costs by eliminating work place waste • Improve equipment further by keeping accurate maintenance records (e.g., MTBF) and analyzing the data in them 23

The Four St eps t o Capabl e Oper at or s and t he Seven St eps of Aut onomous Mai nt enance

7 6

Practice full selfmanage ment

Systematic autonomous maintenance

5 4 3 2 1

Perform general process inspection Conduct general equipment inspection

Establish cleaning and checking standards Address contamination sources and inaccessible places

Production based on the given schedule (focus : production)

Recognizes signs of abnormality; deals with abnormalities correctly; performs periodic overhaul checking and parts replacement correctly

Quality assurance (focus : process)

Detects abnormalities promptly; takes emergency action against abnormalities

Management of deterioration and restoration (focus : machine 　 to process)

Understands properties of materials being handled; performs correct adjustment and setting

Basic conditions to prevent deterioration (focus :

Understands process performance and functions; operates process correctly

24

4

3

2

1

The Five Levels of Operators

• • • • •

Operation only Multi-operations 2 + QC + AM 3 + Improvement 4 + Engineering

25

Autonomous maintenance When equipment does not have the basic condition to be operated and there are many possible causes which may lead to breakdowns, a collective approach by AM without persistently asking why, why, - - - to identify root causes, can work well. But when there are few breakdowns, AM can be very costly. Ø

Ø

Step 2 is the key to get the benefits of AM.

Applying AM Step 1 – 3 is the key to establish the basic condition of the equipment. Ø

Ø

The major economic benefit of AM can be gained by AM Step 1 – 3.

Ø

Step 4 costs time and money.

Depending on the breakdown situation of the equipment applying Step 4 cannot be economically justified. Ø

We need to add something extra activities on Step 4 to get benefits out of it. Ø

26

Autonomous maintenance When equipment does not have the basic condition to be operated and there are many possible causes which may lead to breakdowns, a collective approach by AM without persistently asking why, why, - - - to identify root causes, can work well. But when there are few breakdowns, AM can be very costly. Ø

Ø

Step 2 is the key to get the benefits of AM.

Applying AM Step 1 – 3 is the key to establish the basic condition of the equipment. Ø

Ø

The major economic benefit of AM can be gained by AM Step 1 – 3.

Ø

Step 4 costs time and money.

Depending on the breakdown situation of the equipment applying Step 4 cannot be economically justified. Ø

We need to add something extra activities on Step 4 to get benefits out of it. Ø

Developing an Autonomous Maintenance Program

Two characteristic keys to developing a successful autonomous maintenance program are : • thoroughness • continuity Actual decisive factor is smooth integration with the following two WCM fundamental activities : • focused improvement to create know-how to attack waste and losses systematically • education and training to horizontally expand the know-how created by focused improvement

The Goals of AM

•

•

•

Prevent equipment deterioration through correct o peration and daily checks Bring equipment to its ideal state through restorati on and proper management Establish the basic conditions needed to keep equi pment well-maintained

4. Aut onomous Mai nt enance 4. 1 Why i s Aut onomous Mai nt enance Necessar y? 4. 2 The Ai m of AM 4. 3 St ep 0 : Pr el i mi nar y Act i vi t i es 4. 4 St ep 1 4. 5 The Basi s of Aut onomous Mai nt enance i s I ni t i al Cl eani ng. 4. 6 The I mpor t ance of Cl eani ng 4. 7 Put a Label Wher e Ther e i s Somet hi ng Wr ong. 4. 8 The I mpor t ance of I nspect i on 4. 9 The I mpor t ance of Lubr i cat i on 4. 10 Est abl i sh t he Basi c Equi pment Condi t i ons

Why is Autonomous Maintenance Necessary? Activities to m easure deterioration

* Checking ofoperating condition * Daily checking * Periodicalchecking

Activities to prevent deterioration * Cleaning * Inspection * Bolting Activities to restore deterioration

* M inor adjustm ent * Taking m easures against abnorm alities * Reporting the abnorm ality to the m aintenance departm ent

Functional elements and their troubles Funct i onal el ement

Funct i onal par t

Tr oubl e

Cause

1.

Lubr i cat i on

Lubr i cat i on oi l , gr ease

Sei ze

Lack of l ubr i cat i on oi l , I mpr oper oi l

2.

Bear i ng

Bal l , Rol l er , Pl ai n bear i ng

Sei ze, Vi br at i on

Lack of l ubr i cat i on oi l , Over l oad, Eccent r i ci t y

3. Body of r ot at i on

I mpel l er , Rot or

Shaf t sei ze, Vi br at i on

Unbal ance

4.

Connect i on

Coupl i ng, Gear , Key

Br eakage, Vi br at i on

Eccent r i ci t y, negl ect ed wear

5.

Tr ansmi ssi on

V bel t , Chai n, Cl ut ch

Sl i di ng, Heat

Negl ect ed wear

6.

Seal i ng

Packi ng, Seal i ng mechani sm

Leakage, Expl osi on, Fi r e

Negl ect ed wear , i nsuf f i ci ent f ast eni ng

7. Dust pr ot ect i on

Fi l t er st r ai ner

Bl ocki ng

Lack of cl eani ng, Damaged el ement

8.

Fl ui d cont r ol

Pi pe, Val ve, Or i f i ce

Abnor mal pr essur e, Cl oggi ng, Abnor mal quant i t y of f l ow, Leakage

Negl ect ed f or ei gn body

9.

Fast eni ng

Bol t , Nut ,

Vi br at i on

I nsuf f i ci ent

Ai m of AM

The Aim of AM

The ai m i s t o hel p t he oper at or t o dev el op hi ms el f . I t wi l l be done i n s mal l s t eps . See bel ow t o s ee how he c an go about hi ms el f dev el opment t r ai ni ng. •

Self teaching in classroom While seeing teaching material (actual article) using texts

Discussion of results and supplementary lecture Group discussion, Instructors supplement lecture

Group discussion

Practice

Doubt, group discussion of tasks, Instructors ask questions

Show by self what has been learnt

Practice Practice of normal work method. Instructors correct.

Discussions of results and supplementary lecture Group discussion and discussion by all supplementary lecture

33

STEP 0 – Preliminary Activities

Step 0

5. Preparation Activities 4. Activity Plan 3. Team’s Basic Training 2. Initial Workshop, Model Areas

tep 0

1. Permanent Team

WORLD CLASS MANUFACTURING AUDIT Valladolid Plant, may 2008

34IVECO PRODUCTION SYSTEM AUTONOMOUS MAINTENANCE

Step 0: Model Area MODEL AREA AUTONOMOUS MAINTENANCE SETTING

1) COST DEPLOYMENT

2)

EQUIPMENT CLASSIFICATION

MODEL AREA

‘AA’ CLASS EQUIPMENT WITH MAJOR LOSSES DUE ON COST DEPLOYMENT 35

AM * To start : Definition of machine related waste and losses and their measurement (OEE, OPE) * Root causes : Lack of the basic conditions * Classification of machines

Reactive

Preventive

Proactive

AA

Very big losses based on cost deployment

Very big possible losses

Very big potential losses based on financial risk deployment

A

Big losses based on cost deployment

Big possible losses

Big potential losses based on financial risk deployment

B

Some amount of losses based on cost deployment

Some amount of possible losses

Some potential losses based on financial risk deployment

C

Small losses based on cost deployment

Small possible losses

Small potential losses based on financial risk deployment

36

Link to cost deployment C matrix: breakdowns losses/ute 900

C matrix: K€ guasti / UTE

800

D matrix

700

k€/anno

600 500 400 300 200 100 0 208

222

203

207

205

202

204

201

223

221

UTE

D MATRIX Breakdown analyzed by EWO format

900 800 700

AM

k€/Y

600

PD FI PM AM

500 400 300 200 100 0 208

222

203

207

205 202 UTE

204

201

223

221

37

Before training Spidalieri

After training

Mengo

W CM 3

Attre zzam ento

TPM

Mengo

Spidalieri

METODO AM (7 STEP)

2

Proce dure di ripristino

Team

1 Ca mbio tipo

AM TAGS

WCM 3

WCM 3

0

Attrezza mento

Attrezza mento

TPM

TPM

5 WHYS

METODO AM (7 STEP)

2

Proce dure di ripristi no

METODO AM (7 STEP)

2

Proc edure di ripristino

Ge stione ciclo

1 Cambio tipo

AM TAGS

1

Conosce nza proce sso

OPL

Cambio tipo

Gestione ciclo

0

EQU. ABC CLASSIF.

OEE

0

AM TAGS

Gestione ciclo

a ltri TOOLS (ka ize n, 5S , Poka Yoke, 5W 1H)

5 WHYS

5 WHYS

Conoscenza processo

OPL

EQU. ABC CLASSIF.

OEE

Conoscenza processo

OPL

altri TOOLS (kaizen, 5S, Poka Yoke, 5W 1H)

EQU. ABC CLASS IF.

OEE

altri TOOLS (kaizen, 5S, Poka Yoke , 5W1H)

La Vigna

Aprile Attrezzamento

Attrezzame nto

TPM METODO AM (7 STEP)

2

Procedure di ripristino

La Vigna

Aprile

WCM 3

WCM 3

WCM 3

TPM

AM TAGS

Conoscenza processo

Gestione ciclo

WCM 3

Attrezzamento

OPL

2

Procedure di ripristino

METODO AM (7 STEP)

EQU. ABC CLASSIF.

OEE

altri TOOLS (kaizen, 5S, Poka Yoke, 5W1H)

5 WHYS

TPM

Conoscenza processo

OPL EQU. ABC CLASSIF.

OEE

Procedure di ripristino

1

altri TOOLS (kaize n, 5S, Poka Yoke, 5W1H)

Cambio tipo

1

TEAM

AM TAGS

METODO AM (7 STEP)

AM TAGS 0

5 WHYS

2

TPM

2

Proce dure di ripristino

Cambio tipo

0 Gestione ciclo

W CM 3

Attrez zamento

1

1 Cambio tipo

METODO AM (7 STEP)

Attrezzamento

METODO AM (7 STEP)

2

Procedure di ripristino

Cambio tipo

5 W HYS 0

AM TAGS 0

Gestione ciclo

Ge stione ciclo

5 WHYS

Conoscenz a processo

OPL

Conoscenza processo

OPL

EQU. ABC CLASSIF. altri TOOLS (ka ize n, 5S, Poka Yoke, 5W1H)

OEE

EQU. ABC CLASSIF.

OEE

altri TOOLS (kaizen, 5S, Poka Yoke, 5W1H)

1

Cambio tipo

Iacobucci WCM 3

Attrezzamento

AM TAGS

Iacobucci

0

WCM 3

Gestione ciclo

TPM

Attrezzame nto METODO AM (7 STEP)

2

Procedure di ripristino

Caradonia

W CM 3

METODO AM (7 STEP)

2

Procedure di ripristino

Caradonia

5 WHYS

TPM

Attrezzamento

W CM 3

METODO AM (7 STEP)

Attrezzamento METODO AM (7 STEP)

2 1 Cambio tipo

AM TAGS

Cambio tipo

OPL AM TAGS

0

Procedure di ripristino

5 WHYS

Conoscenza processo

Gestione ciclo

EQU. ABC CLASSIF.

OEE

Cambio tipo

5 W HYS

5 WHYS

Cambio tipo

5 WHYS

0

altri OPL TOOLS (kaizen, 5S, Poka Yoke, 5W1H) EQU. ABC

0

Gestione ciclo

CLASSIF.

OPL

Conoscenza processo

altri TOOLS (kaize n, 5S, Poka Yoke, 5W1H)

altri TOOLS (kaizen, 5S, Poka Yoke, 5W1H)

AM TAGS

1

1

EQU. ABC CLASSIF.

OEE

Conoscenza processo

OPL

Procedure di ripristino

AM TAGS

0

Gestione ciclo

OEE

2

1

Conoscenza processo

Gestione ciclo

OPL

EQU. ABC CLASSIF.

Conoscenza processo

altri TOOLS (ka ize n, 5S, Poka Yoke, 5W 1H)

OEE

EQU. ABC CLASSIF. altri TOOLS (kaizen, 5S, Poka Yoke, 5W1H)

OEE

Colasanto

Caiola Attrezzamento

TPM METODO AM (7 STEP)

2

Procedure di ripristi no

WCM 3

WCM 3

WCM 3 Attre zzamento

Colasanto Attrezzamento TPM

METODO AM (7 STEP)

2

Procedure di ripristino

METODO AM (7 STEP)

2

Procedure di ripristino

Caiola

WCM 3

Attrezzamento

AM TAGS

AM TAGS

Cam bio tipo

AM TAGS

5 WHYS

Conoscenza processo

5 WHYS

OPL

OEE

5 WHYS

Conoscenza processo

WCM 3

Attrezzamento

METODO AM (7 STEP)

Di Nunzio WCM 3 Attrezz am ento

TPM METODO AM (7 STEP)

2

Procedure di ripristino

Cambio tipo

AM TAGS

Conoscenza processo

OPL EQU. ABC CLASSIF.

altri TOOLS (kaizen, 5S, Poka Yoke, 5W1H)

AM TAGS

5 WHYS

Conoscenza processo

OPL EQU. ABC CLASSIF.

altri TOOLS (kaizen, 5S, Poka Yoke, 5W 1H)

TOOLS (kaizen, 5S, Poka Yoke, 5W1H)

Martino Attrezzame nto

WCM 3

TPM

1

Cambio tipo

5 W HYS

Cambio tipo

AM TAGS 0

Gestione ciclo

Ge stione ciclo

Conosce nz a proce sso

METODO AM (7 STEP)

2

Procedure di ripristino

0

Gestione ciclo

OEE

OEE

METODO AM (7 STEP)

AM TAGS

0

5 WHYS

EQU. ABC CLASSIF. altri

1

Cambio tipo

0 Gestione ciclo

OPL

Conoscenza processo

2 Procedure di ripristino

1

1

EQU. ABC CLASSIF. altri TOOLS (kaizen, 5S, Poka Yoke, 5W1H)

OEE

W CM 3

TPM

2

EQU. ABC CLASSI F.

Martino

Gestione ciclo

OPL

Conosce nza processo

altri TOOLS (kaizen, 5S, Poka Yoke, 5W1H)

Di Nunzio

5 WHYS 0

Gestione ciclo

OPL

OEE

a ltri TOOLS (kaizen, 5S, Poka Yoke , 5W1H)

Cambio tipo

0

Gestione ciclo

EQU. ABC CLASSIF.

OEE

Cambio tipo

0

0 Gestione ciclo

Procedure di ripristino

AM TAGS

1

1 1

1 Cambio tipo

Attrezzamento

METODO AM (7 STEP)

2

Procedure di ripristino

5 WHYS

OPL

38 OEE

EQU. ABC CLASSIF. altri TOOLS (ka izen, 5S, Poka Yoke , 5W 1H)

Conoscenza processo

OPL

OEE

EQU. ABC CLASSIF.

altri TOOLS (kaizen, 5S, Poka Yoke, 5W1H)

St ep 1

St ep 1: Per f or m I ni t i al Cl eani ng •

El i mi nat e di r t , dust , and gr i me

•

Expose al l abnor mal i t i es

•

Cor r ect mi nor f l ows and est abl i sh basi c equi pment condi t i ons

St ep1: Per f or m i ni t i al cl eani ng

Activities •

•

•

El i mi nat e dust ant di r t f r om mai n body of equi pment Expose i r r egul ar i t i es such as sl i ght def ect s, cont ami nat i on sour ces, i naccessi bl e pl aces, and sour ces of qual i t y def ect s El i mi nat e unnecessar y and sel dom- used i t ems, and si mpl i f y equi pment

St ep1: Per f or m i ni t i al cl eani ng

Hardware Goals (Keys for workplace audits) •

•

Pr event accel er at ed det er i or at i on by el i mi nat i ng t he envi r onment al st r ess of dust and di r t Rai se t he qual i t y of checki ng and r epai r wor k and r educe checki ng and r epai r t i mes by el i mi nat i ng dust and di r t

•

Est abl i sh basi c equi pment condi t i ons

•

Expose and deal wi t h hi dden def ect s

St ep1: Per f or m i ni t i al cl eani ng

Human Goals (Keys for SGA audits) •

•

•

Get oper at or s i n t ouch wi t h t hei r equi pment t o make t hem mor e f ami l i ar wi t h i t , devel op a sense of owner shi p and concer n, and st i mul at e t hei r cur i osi t y about i t Enabl e gr oup l eader s t o l ear n about l eader shi p by i mpl ement i ng t hi s st ep i n smal l gr oups Enabl e peopl e t o r ecogni ze sl i ght def ect s and ot her i r r egul ar i t i es

St ep1: Per f orand m i Staff ni t i al(fostering cl eani ng Roles of Managers motivation, ability, and opportunity) •

•

•

Expl ai n t he r el at i onshi p bet ween c ont ami nat i on and accel er at ed det er i or at i on ( mai nt ai nabi l i t y) – t hat i s, expl ai n t he meani ng of “opt i mal c ondi t i ons ” Poi nt out t he most i mpor t ant par t s t o k eep cl ean and expl ai n t he i mpor t ance of basi c equi pment condi t i ons ( cl eani ng, l ubr i cat i ng, and t i ght eni ng) . Teach usi ng nut s, bol t s and l ubr i c at i on manual s Expl ai n t he s i gni f i cance of “i nspect i on

STEP 1 Practice full selfmanagement

Step 7Systematize autonomous maintenance

Step 6Perform general process

Preliminary activities

inspection

Step 5Conduct general equipment inspection

Step 4

0

Establish cleaning and checking standards

Step 3Address contamination Step 2

sources and inaccessible places

Perform initial cleaning

WORLD CLASS MANUFACTURING AUDIT Valladolid Plant, may 2008

IVECO PRODUCTION SYSTEM AUTONOMOUS MAINTENANCE

The Basis of Autonomous Maintenance is Initial Cleanin g. Start with cleaning by yourselfwith waste.

1.Inspect even the inside ofthe m achine.

2.Trace the source of dust and dirt.

Cleaning is inspection.

The I mpor t ance of Cl eani ng

Why cl ean ? •

Dust damages machi nes.

Det ai l ed cl eani ng t o r emove al l cont ami nat i on ensur es t hat al l par t s of equi pment i s t ouched. Onl y i n t hi s way can we f i nd hi dden def ect s.

The I mpor t ance of Cl eani ng Harmful Effects of Inadequate Cleaning Fai l ur e

Di r t and f or ei gn mat t er penet r at es r ot at i ng par t s, sl i di ng par t s, pneumat i c and hydr aul i c syst em, el ect r i cal syst em, and sensor s, et c. , causi ng l oss of pr eci si on, mal f unct i on, and f ai l ur e as a r esul t of wear , bl ockage, f r i ct i onal r esi st ance, el ect r i cal f aul t s, et c.

Qual i t y Def ect s

Qual cont mat t mal f

Accel er at ed Det er i or at i on

Accumul at ed dust and gr i me make i t di f f i cul t t o f i nd and r ect i f y cr acks, excessi ve pl ay, i nsuf f i ci ent l ubr i cat i on, and ot her di sor der s, r esul t i ng i n accel er at ed det er i or at i on.

Speed Losses

Dust and di r t i ncr ease wear and f r i ct i onal r esi st ance, causi ng speed l osses such as i dl i ng and under per f or mance.

i t y def ect s ar e caused ei t her di r ect l y by ami nat i on of t he pr oduct wi t h f or ei gn er or i ndi r ect l y as a r esul t of equi pment unct i on.

Key poi nt s f or cl eani ng

•

•

•

•

•

Cl ean equi pment r egul ar l y as par t of dai l y wor k . Cl ean deepl y ― r emov e al l t he l ay er s of gr i me and s c al e bui l t up ov er many y ear s Open pr ev i ous l y i gnor ed c ov er s , guar ds , and s o on, t o ex pos e and r emov e ev er y s pec k of di r t f r om ev er y c or ner and c r ev i c e. Cl ean at t ac hment s and ac c es s or i es as wel l as mai n uni t s , e. g. , c onv ey i ng equi pment , c ont r ol box es , and l ubr i c ant t ank s ( bot h i ns i de and out ) . Do not gi v e up when a par t get s di r t y agai n s oon af t er c l eani ng. I ns t ead, c ar ef ul l y not e how l ong i t t ak es t he par t t o bec ome c ont ami nat ed agai n, wher e t he c ont ami nat i on i s c omi ng f r om, and how s ev er e i t i s .

( 1) Cl eani ng of t he f l oor

On t he f l oor

St ar t i ng f r om cl eani ng of t he f l oor

　　 Cl eani ng of t he f l oor i s qui t e eas y to tackle with 　 and is very efficient in creating clean atmosphere 　 within the shop. 　　 It contributes a great deal in giving workers 　 comfort 　 ability. 　　 This is the topic that is to be considered right 　 after eliminating unnecessary items.

Mai n st eps : 1. Fi r st , cl ean by br ooms 2. Dr aw sect i on l i nes 3. Tr y t o shut out dust and st ai n 4. Ver y f i ne cl eani ng

1.

Fi r s t , c l ean by br ooms

* Sect i on chi ef s or l eader s t hemsel ves must t ake br ooms and t ake t he l ead i n cl eani ng

2.

Dr aw s ec t i on l i nes

* Sect i on l i nes of passages * I ndi cat i on on t he f l oor of 　 car r i er s, t he st or i ng pl ace 　 of i n- pr ocess 　 i nvent or y, 　 and t he sect i ons wher e i t 　 i s pr ohi bi t ed t o put t hi ngs. * Pi ct ur es on t he f l oor t o show 　 t he f i xed posi t i ons of smal l 　 f aci l i t i es such as gar bage can, 　 ash t r ays or f i r e

3.

I mpr ov ement t o s hut out t he s our c e of dus t 　 and s t ai n

* Oi l l eakage f r om machi nes 　 By cl eani ng i nspect i on of machi nes, f i nd t he pl ace 　 wher e oi l i s l eaki ng and i mpr ove i t . * Wat er l eakage f r om t anks or pi pes Regi st er t hem and i mpr ove one by one. * Mi st , dust or chi ps 　　 I mpr ovement of t he cr evi ce bet ween t he cover and 　 t he body, or t he pr oper i nst al l at i on of t he cover 　　 I nspect i on of t he suct i on syst em

Poi nt s I nv ol v ed: •

El i mi nat i ng t he pr obl em of cl eani ng har d- t o- r each pl aces

Ex pec t ed Benef i t s : •

Rat i onal i z es cl eani ng oper at i ons t o st r eaml i ne wor k pl ace

Manuf act ur i ng of t en pr oduces di r t and shavi ngs t hat must be cl eaned

har d t o cl ean easy t o cl ean

Wr ap and suspend cor ds and pi pes cor ds and pi pes

cover Thi s cl ear s t he f l oor , maki ng i t easy t o cl ean

Cl osed pal l et ends make cl eanup easi er

Poi nt s I nv ol v ed:

Ex pec t ed Benef i t s :

pans ar e not necessar y unl ess t her e ar e oi•5S l lcan eaksbe mor e ef f ect i ve • A compl et el y ef f i ci ent wor kpl ace can be achi r n t o i dent i f y t he causes of oi l l eaks

St op t he oi l l eak and el i mi nat e t he oi l pan!

Us i ng an oi l pan has kept t he sur r oundi ng ar ea cl ean, but t he cause of oi l l eak i t sel f has not been sol ved

To do t hi s:

1.

2.

3. 4.

Compl et el y mop up t he oi l t hat has l eaked Obser ve f or a whi l e, unt i l oi l st ai ns appear Tr ace t hese t o t hei r sour ce Typi cal causes: l oose bol t s and nut s, packi ng def ect s

* Adher ence of past e- l i ke t hi ng causes scat t er i ng or 　 dr i ppi ng. 　　 I mpr ovement of t he par t t hat causes scat t er i ng or 　 dr i ppi ng. 　　 I mpr ovement of t he i nj ect i on met hod and r et r i eval 　 met hod. 　　 Adopt i on of r emoval sheet s. * Car r yi ng i n and out of dust or st ai n 　　 A dust r emovi ng mat t r ess shoul d be pl aced at 　 t he ent r ance. I t shoul d not be necessar y f or a 　 wor ker t o st op on t he mat t r ess but j ust t o pass on 　 i t so t hat dust must be r emoved aut omat i cal l y.

4. Fi ne l evel of cl eani ng

* Cl eani ng of oi l t hat i s st ai ned on t he f l oor 　　 - - Cl eanser must be used and t he f l oor must be 　 　　　　 cl eaned r epeat edl y. * Wax or pai nt i s t o be appl i ed t o pr event dust f r om　 concr et e. 　 At pr eci si on needed f act or i es wher e dust or st ai n i s 　　 l east wel come, t he f l oor must be cl eaned 　 t o t he ext ent t hat i t can be t ouched 　 wi t h cl ean hands. 　 Such cl eani ng shoul d be ext ended 　 　 t o t he wal l or ot her par t s of 　

( 2) I mpr ovi ng chr oni c qual i t y def ect whi ch i s caused di r ect l y by dust or st ai n

Thi s must be car r i ed out by t he cooper at i on of t he l i ne peopl e and t he t echni cal st af f

* Typi cal exampl es: 　 Dust and l umps i n pai nt i ng 　 Noi se of pr eci si on r ot at i ng par t s whi ch r equi r e good sound char act er i st i cs 　 St r eaks on t he met al of t he r ot at i ng 　 machi ne 　 Cr unches of oi l pr essur ed machi nes

　 Dust on opt i cal i nst r ument s 　 For ei gn body on chemi cal or medi cal 　 appl i ances 　 Smal l i r r egul ar unevenness of a pr eci si on 　 pl at e maki ng pl ant 　 I r on cont ami nat i on at a pot t er y pl ant 　 Dust or noi se of pr eci se el ect r omagnet i c 　 pr oduct s 　 St ai n at a dye- pr ocess pl an 　

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Mai n poi nt s t o be at t ended:

　　 Tr y t o f i nd out

t he t r ue causes f or dust or 　 st ai n - - Col l ect def ect i ve sampl es and 　 check by a mi cr oscope. 　　 Anal yze t he r out es of t he out br eak, i nvasi on, 　 and cont agi on of dust and st ai n. 　　 Thor ough cl eani ng of t he envi r onment s .

* Thor ough cl eani ng of t he envi r onment 　　 Fl oor s,

wal l s, shel ves 　　 Upper sur f ace, i nsi de and l ower machi nes or f i xt ur es 　　 Cei l i ng, cor ner s of t he cei l i ng, of pi pes 　　 Upper sl i de of l amp shades 　　 Upper and l ower sur f aces of shel 　 and oper at i onal st ands 　　 I nsi de and out si de of t he cont ai 　 f or t r anspor t at i on and st or age 　　 Wi t h t hese measur es, chr oni cl e 　 def ect due t o dust or st ai n 　 wi l l al most be el i mi nat ed

sur f ace of 　 upper par t ves ner s

* Exampl es of bl i nd poi nt s :

　　 Dust wi t hi n t he admi ssi on duct t o a cl ean r oom 　　 Cushi ons and such t o be br ought i nt o a 　 cl ean r oom 　　 Mi nut e dust by ai r bl ow 　　 Oi l mi st i n t he exhaust of 　 an ai r cyl i nder or i n t he 　 l eaked ai r 　　 Di r t y washi ng l i qui d

* Anal ysi s of how dust comes i n and cr eat e t r oubl es 　　 Fol l owi ng i s an exampl e of

sheet met al

pr essi ng: ・・ I t i s easy t o r ecogni ze t hat t he r out es of i nf ect i on of dust comi ng i n and causi ng t r oubl es ar e enor mous.

For ei gn body comi ng in wi t h moul ds t hat ar e kept out si de

Moul d

A wi r e t ouches t he f l oor or i s pl aced on t he f l oor A moul d t ouches t he gr ound when dr i ven by t he cr ane Tr anspor t at i on

A pr ot ect i on boar d i s pl aced di r ect l y on t he f l oor Wi pe t he shoot by a wast e f or ei gn body l i ke bur r ) Al i en subst ances st i cks t o set t i ng t ool s or measur i ng t ool s Set t i ng of t he moul d

Met al powder comi ng out of sander s or 　 gl i nder s i n a moul d r epai r shop

Sawdust spr ead agai nst oi l l eakage

Dus t c omes down f r om t he bol t hol es of t he upper moul d Dust comes down f r om t he ai r hol e of t he upper moul d

Dust comes down f r om t he sl i de openi ng Pr ocessi ng

For ei gn body on t he moul d sur f ace For ei gn body on t he

Mat er i al

Mai n r out e of dus t t r ans f er

I n or der t o put a wi r e ar ound a moul d, a wor ker st ands on i t wi t h hi s shoes

Bur r by shear i ng, 　 bor i ng, or pi er ci ng Wooden wast e comes out f r om br oken wooden sur f ace pl at e

For ei gn body on a gl ove i s adher ed t o

For ei gn body i s br ought i n at t he t i me of oi l char ge

For ei gn body on a conveyor bel t i s adher ed t o

For ei gn body of a l eat her gl ove i s r ubbed agai nst t he mat er i al

mat er i al sur f ace

A br ush f or oi l char ge t ouches t he out si de of moul ds or f r ames

Fr ames or moul ds ar e t ouched by hands dur i ng r ecei vi ng and del i ver y of mat er i al

Unevenness c aus ed by al i en s ubst anc es

Sour c e of dust

On pal l et s f r om out si de 　 t he pl ant

I f I cl ean my equi pment t hor oughl y, I won’ t over l ook mi nor f l aws.

Poi nt of cl eani ng ( Gl asses of an oi l l evel er and i nst r ument )

Cannot see t he exi st ence of oi l and t he degr ee of cont ami nat i on

Oi l l evel er

Cannot see t he scal e

I nst r ume nt s

Poi nt of cl eani ng ( Li mi t swi t ches) Remove at t ached dust and di r t .

Poi nt of cl eani ng ( Lenses of a phot o cel l ) Cl ean wi t h a sof t cl ot h. .

El i mi nat e di r t , dust , and gr i me

Tur n cl eani ng i nt o i nspect i o n.

Equi pment

St op accel er at ed det er i or at i on!

Equi pment

St op checks ar e a chance to di scover abnor mal i t i es and det er i or at i on!

Expose al l abnor mal i t i es When cl eani ng, answer t he f ol l owi ng sor t s of quest i ons:

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What c an go wr ong i f t hi s par t i s di r t y ? What happens t o t hi s c ol umn or pi pe when t hi s par t i s r us t y ? How woul d t he pr oduc t be af f ec t ed i f t hi s wer e bl oc k ed? Thi s par t k eeps on get t i ng di r t y no mat t er how of t en I c l ean i t . Wher e does t he c ont ami nat i on c ome f r om?

Exposi ng seven t ypes of abnor mal i t y Abnor mal i t y

Exampl es

1. Mi nor Fl aws

• • • • •

Cont ami nat i on Damage Pl ay Sl ack nes s Abnor mal phenomena

• Adhes i on

2. Unf ul f i l l ed Basi c Condi t i ons

• • • •

Lubr i Lubr i Oi l l Ti ght

cat i on cant s uppl y evel gauges eni ng

Dust , di r t , powder , oi l , gr ease, r ust , pai nt Cr acki ng, cr ushi ng, def or mat i on, chi ppi ng, bendi ng Shaki ng, f ai l i ng out , t i t l i ng, eccent r i ci t y, wear , di st or t i on, cor r osi on Bel t s, chai ns Unusual noi se, over heat i ng, vi br at i on, st r ange smel l s, di scol or at i on, i ncor r ect pr essur e or cur r ent Bl ocki ng, har deni ng, accumul at i on of debr i s, peel i ng, mal f unct i on I nsuf f i ci ent , di r t y, uni dent i l ubr i cant Di r t y, damaged, or def or med l l ubr i cant pi pes Di r t y, damaged, l eaki ng; no i Nut s and bol t s: sl ackness, mi l ong, cr ushed, cor r ect ed, washer unsui t abl e, wi ng nut s

f i ed, unsui t abl e, or l eaki ng

Machi ne const r uct i on, cover s, Cover s, const r uct i on, l ayout , or i ent at i on, oper at i ng- r ange Posi t i on of l ubr i cant i nl et , f oot hol ds, l ubr i cant out l et ,

l ayout , f oot hol d, space i nst r ument posi t i on and di spl ay const r uct i on, hei ght , space

ubr i cant i nl et s, f aul t y ndi cat i on of cor r ect l evel ssi ng, cr oss- t hr eaded, t oo on backwar d

3. I naccessi bl e Pl aces

• • • • •

Cl eani ng Check i ng Lubr i cat i ng Ti ght eni ng Oper at i on

Exposi ng seven t ypes of abnor mal i t y

Abnor mal i t y 4. Cont ami nat i on Sour ces

• • • • •

Pr oduct Raw mat er i al s Lubr i cant s Gases Li qui ds

• Sc r ap • Ot her

5. Qual i t y Def ect Sour ces

• • • • • •

For ei gn mat t er Shock Moi st ur e Gr ai n si ze Concent r at i on Vi scosi t y

Exampl es Leaks, spi l l s, spur t s, scat t er , over f l ow Leaks, spi l l s, spur t s, scat t er , over f l ow Leaki ng, spi l l , and seepi ng l ubr i cat i ng oi l s, hydr aul i c f l ui ds, f uel oi l , et c. Leaki ng compr essed ai r , gases, st eam, vapor s, exhaust f umes, et c. Leaki ng, spi l t and spur t i ng col d wat er , hot wat er , hal f f i ni shed pr oduct s, cool i ng wat er , wast e wat er , et c. Fl ashes, cut t i ngs, packagi ng mat er i al s, and nonconf or mi ng pr oduct Cont ami nant s br ought i n by peopl e, f or k- l i f t t r ucks, et c. and i nf i l t r at i ng t hr ough cr acks i n bui l di ng I ncl usi on, i nf i l t r at i on, and ent r ai nment of r ust , chi ps, wi r e scr aps, i nsect s, et c. Dr oppi ng, j ol t i ng, col l i si on, vi br at i on Too much, t oo l i t t l e, i nf i l t r at i on, def ect i ve el i mi nat i on Abnor mal i t i es i n scr eens, cent r i f ugal separ at or s, compr essed- ai r separ at or s, et c. I nadequat e war mi ng, heat i ng, compoundi ng, mi xi ng, evapor at i on, st i r r i ng, et c. I nadequat e war mi ng, heat i ng, compoundi ng, mi xi ng,

Exposi ng seven t ypes of abnor mal i t y

Abnor mal i t y 6. Unnecessar y and Nonur gent i t ems

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Machi ner y Pi pi ng equi pment Measur i ng i nst r ument s El ect r i c al equi pment Ji gs and t ool s Spar e par t s Makes hi f t r epai r s

Exampl es Pumps, f ans, compr essor s, col umns, t anks, et c. Pi pes, hoses, duct , val ves, damper s, et c. Temper at ur es, pr essur e gauges, vacuum gauges, ammet er s, et c. Wi r i ng, pi pi ng, power l ead, swi t ches, pl ugs, et c. Gener al t ool s, cut t i ng t ool s, j i gs, mol ds, di es, f r ames, et c. St andby equi pment , spar es, per manent st ocks, auxi l i ar y mat er i al s, et c. Tape, st r i ng, wi r e, met al pl at es, et c.

7. Unsaf e pl aces

• • • • • •

Fl oor s St eps Li ght s Rot at i ng machi ner y Li f t i ng gear Ot her

Unevenness, t r amps, pr oj ect i ons, cr acki ng, peel i ng, wear ( st eel deck pl at es) Too st eep, i r r egul ar , peel i ng ant i - sl i p cover i ng, cor r osi on, mi ssi ng handr ai l s Di m, out of posi t i on, di r t y or br oken cover s, not pr oper l y expl osi on- pr oof ed Di spl aces, f al l en of f or br oken cover s, no saf et y or emer gency st op devi ces Wi r es, hooks, br akes, and ot her par t s of cr anes and hoi st s Speci al subst ance, sol vent s, t oxi c gases, i nsul at i ng mat er i al s, danger si gns pr ot ect i ve cl ot hi ng, et c.

Expose al l abnor mal i t i es When cl eani ng, answer t he f ol l owi ng sor t s of quest i ons: •

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What pr obl ems c an oc c ur i f t hi s nut or bol t i s l oos e or mi s s i ng? What pr obl ems c an oc c ur i f t hi s oi l i s di r t y or us ed up? What pr obl ems c an oc c ur i f t hi s V- bel t or c hai n i s s l ac k ? Pr ovi de l ear ni ng ai ds. ( c f . Ex pos i ng s ev en t y pes of abnor mal i t y ) Devel op one- poi nt l essons. ( c f . Appendi x ) Tag abnor mal i t i es wher e t hey occur .

Put a Label Where There is Something Wrong.

Tag abnor mal i t i es One- poi nt l esson 1.

2.

3.

Basi c knowl edge about equi pment mai nt enance Act ual exampl es of br eakdowns and def ect s Exampl es of equi pment i mpr ovement s

Use one- poi nt l essons

A good exampl e of t aggi ng

eakage on t he r od

of t he cyl i nder when i t moves

Check items 1.

How is the oil pressure?

2. 　 How is the movement of the cylinder? 4.

What is the reason for the poor operation?

Tagging Higher pressure.

The strainer is clogged.

Why was the strainer clogged? Oil was dirty. 　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　 clean the tank. Why did the oil get dirty? cutting oil from

Restore to the right pressure. 　

Slow Does not move.

6.

8.

Detagging

Dust comes into the tank.

Clean the strainer. 　 Remove the oil and Prevent chips and dispersion.

３３３ Check items

6. Why did dust come in?

Tagging

Detagging

There are holes and spaces in the upper cover of the

Cover the holes and spaces.

tank. How is movement?

Good, but there is oil

Dismantle the section

O ring was cut.

Replace the O ring.

11.

What is the reason for oil leakage? What is the reason for it?

Remove the scratch

13.

Why were the scratches

There are scratches on the rod. Dispersed chips are attached to the rod.

7.

9.

Take countermeasures against dispersion of

produced chips. 15.

How are the movement? Leakage? Oil temperature?

Good. None Appropriate

Make one-point lessons.

Teachi ng t eammat es wi t h a one- poi nt l es son

The I mpor t ance of

I nspect i on

Why inspect ? •

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Inspection traces the conditions of areas known to be prone to defect. Inspection leads to understanding and ownership of what and how to control conditions and make the job easy.

When some part, if it breaks, has a risk of creating a huge damage, then it must be placed to expose it to human eyes such that its anomaly can be detected quickly enough even if such placement looks ugly. (eg. The rupture of hoses, breakdowns of cables)

The I mpor t ance of

I nspect i on

Key Points for Inspection •

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•

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Sear ch f or i nvi si bl e as wel l as vi si bl e def ect s, such as l ooseness, subt l e vi br at i ons, and sl i ght over heat i ng t hat onl y t ouch can det ect . Sear ch car ef ul l y f or wor n pul l eys and bel t s, di r t y dr i ve chai ns, bl ocked suct i on f i l t er s, and ot her pr obl ems l i kel y t o l ead t o mal f unct i ons. Not e whet her equi pment i s easy t o cl ean, l ubr i cat e, i nspect , oper at e, and adj ust . I dent i f y hi ndr ances such as l ar ge, obst r uct i ve cover s, i l l - posi t i oned l ubr i cat or s, and so on. Ensur e t hat al l met er s oper at e cor r ect l y and ar e cl ear l y mar ked wi t h t he speci f i ed val ues. I nvest i gat e any l eaks of pr oduct , st eam, wat er , oi l , compr essed ai r , and so on. Al so hunt f or hi dden pr obl ems such as cor r osi on i nsi de i nsul at i ng mat er i al s on pi pes, col umns, and t anks, and bl ockages i nsi de chut es and duct s.

( 1) I nspect i on by cl eani ng of equi pment

　 Thr

ough cl eani ng, even a nonspeci al i st can det ect 　 some def ect whi ch ot her wi se may not be not i ced.

　 Thi s i s cal l ed i nspect i on by cl eani ng.

* Di r t y machi nes wi l l cause many t r oubl es. Di r t y mac hi nes ar e not cl eaned 　 pr oper l y. Because t hey ar e not cl eaned, t hey have not been i ns pect ed t hor oughl y. Because t hey ar e not i nspec t ed t hor oughl y, t he def ec t s t hat wi l l cause t r oubl es ar e hi dden. ( hot bed of wast e) Thi s i s why di r t y machi nes cr eat e a l ot of t r oubl es.

* Change f r om t he shop wi t h many t r oubl es t aki ng pl ace one af t er anot her i nt o t he shop of per f ect pr oduct i on - St ar t wi t h i nspect i on by cl eani ng ve ecti def rate

I f many t r oubl es t ake pl ace one af t er anot her al t hough cer t ai n count er measur es have been t aken, t r y t o i nspect t he machi ne by cl eani ng and make mi nut e i mpr ovement s st ep by st ep.

y ilit Fac et N ncy icie f Ef

Inspection by cleaning

Defect Productive

( 2) How t o car r y out i nspect i on by cl eani ng Tur n cl eani ng i nt o i nspect i on!

The V bel t i s wor n!

The oi l suppl y pi pe i s t ouchi ng it!

Ther e’ s cut t i ng oi l on t he l i mi t swi t ch

* Mai n i t ems: 　　 St udy t he si t uat bef or ehand. 　　 I nspect i on by cl 　　 Par t i ci pat i on of t echni ci ans. 　　 I nvest i gat i on of def ect s.

i on eani ng. speci al i zed mi nor

* Si t uat i on st udy bef or ehand - i n a meet i ng ３ of per sonnel i n char ge 　　 Dat a ar e t o be t aken on at

what pl ant and what ki nd 　 of t r oubl es ar e t aki ng pl ace. 　　 The causes of t he mai n t r priar oubl es investigation ar e t o be 　 　　 i nvest i gat ed. 　　 Col l ect i t ems t hat ar e supposed 　 　　 t o cause t he t r oubl es.

( 3) I nspect i on by cl eani ng : mai n check poi nt s

* Mechani sms of t abl es, sl i di ng beds or ３ r ot at i ng par t s 　 Mai n check poi nt s: 1. Di f f er ence i n hei ght or dent by dust , st ai n, cr unch or wear of sl i di ng beds 2. Damage or wear of t he dust wi per of t he sl i di ng beds 3. Backl ash of sl i di ng beds or r ot at i ng par t s or l oose

* Mai n check poi nt s common t o " movi ng" machi nes such as machi ne t ool s, pr ocessi ng machi nes or assembl y equi pment . 　 Lubr i cat i ng oi l equi pment Oi l s uppl y mout h

Tank

Pi p e

Each oi l s uppl y sect i on

I nspect i on by cl eani ng i s done i n t he above or der .

•

Mai n check poi nt s

1. Check i f i t i s di r t y ar ound t he end of t he oi l suppl y pi pe or check i f t he cover i s not br oken. 2. check t he oi l wi t hi n t he t ank ( compar ed wi t h new oi l ) .

　 Hydr aul i c equi pment Oper at i ng oi l t ank

Oper at i ng oi l pump

Cont r ol pi pes

Act uat or s

I nspect i on by cl eani ng i s done i n t he above or der . 　 Mai n check poi nt s : 1. Check i f i t i s di r t y ar ound t he end of t he oi l suppl y pi pe or ai r br eat her . 2. Check i f t her e i s any openi ng or space t o l et dust i nt o t ank. 3. Check t he oper at i on oi l

　 Pneumat i c equi pment

A set of 3 ai r suppl y equi pment

Cont r ol pi pes

Act uat o rs

Ai r escape

I nspect i on by cl eani ng i s done i n t he above or der .

　 Mai n check 1. Check i f f i l t er i s di char ged bowl i s not di r t y.

poi nt s: t he dr ai n wi t hi n t he ai r sor i f t he i nsi de of t he

2. Check i f t he exhaust gas si l encer i s bl ocked.

* El ect r i c equi pment , cont r ol equi pment 　　 Mai n c hec k poi nt s : 　 1.

Check i f t he t ape r eader sect i on of NC 　 machi nes i s not di r t y or i f l amps ar e di r t y.

　 2. Check i f f i xed scr ews l i ke l i mi t swi t ches ar e 　 not l oose or act uat or , 　 r ol l er s or pl unger s 　 ar e not damaged.

( 4) Par t i ci pat i on of exper t t echni ci ans * Not onl y oper at or s but t he f ol l owi ng exper t t echni ci ans ar e t o par t i ci pat e i n t he i nspect i on by cl eani ng. 　 Pr oduct t echni ci mat er i met hods

i on ans al , or f

t echni ci ans - - exper t on pr oduct s, pr ocessi ng aci l i t i es

　 Faci l i t y t echni ci ans - - exper t t echni ci ans on pr act i cal use of f aci l i t i es, mechani sms, el ect r i c equi pment s 　 Ot her exper t t echni ci ans on

Production technicians

Facility technicians

Other expert technicians

[ A r epor t by an exper t pr oduct i on t echni ci an who has sol ved a f r equent l y occur r i ng t r oubl e of an aut omat i c machi ne] " so f ar we had t r i ed t o check a t r oubl e casual l y and 　 t her ef or e coul d not sol ve i t compl et el y. But when 　 we st ar t ed t o adopt i nspect i on by cl eani ng met hod, 　 we checked each sect i on i n det ai l , i n t he consequence we coul d br eak t hr ough and sol ve t he 　 pr obl em event ual l y. "

( 5) I nvest i gat i on of mi nut e def ect s besi des i nspect i on by cl eani ng

* I nspect i on by cl eani ng i s t he ent r ance t hat l eads t o 　 t he sol ut i on of chr oni c t r oubl es. * However , i nspect i on by cl eani ng does not al ways 　 det ect al l t he def ect s t hat cause t r oubl es.

* Ther ef or e, on t he basi s of t he cur r ent si t uat i on of t he 　 f aci l i t i es, st udi ed t hr ough i nspect i on by cl eani ng, det ai l ed i nvest i gat i on on t he r el at i onshi p bet ween causes and t he ef f ect f or each t r oubl e must be car r i ed out i n or der t o i mpr ove t he si t uat i on.

I f you l et sl i ght l y abnor mal condi t i ons accumul at e, t he pr obl em wi l l get bi gger . . .

* Mai n poi nt s 　　 Tr oubl es on qual i t y of t he mat er i al or 　 t he pr evi ous pr ocess 　　 Ot her t r oubl es of f aci l i t i es, moul ds, or 　 j i gs and t ool s 　　 Tr oubl es by oper at i on met hods, 　 pr ocessi ng condi t i ons, or handl i ng 　 condi t i ons

material

quality of previous 　 process

moulds Handling 　 conditions Machining 　 conditions Operation

jigs tools

facilities

The I mpor t ance of Lubr i cat i on

Why l ubr i cat e ? •

Reduce f r i ct i on and wear

•

Dampen shock

•

Cool movi ng el ement s

•

Pr event cor r osi on

•

Seal out di r t

Poor l ubr i cat i on dest r oys machi nes !

Leaki ng oi l , poor gr easi ng, no l ubr i cat i on r egi me c massi vel y accel er at ed wear and t ear .

Not e t he f ol l owi ngs : •

•

•

•

Oper at or s ar e not t aught t he pr i nc i pl es of l ubr i c at i on or pr obl ems t hat i mpr oper l ubr i c at i on c an c aus e. Far t oo many di f f er ent t y pes of l ubr i c ant ar e us ed and t oo many l ubr i c at i on s i t es ar e i nac c es s i bl e. Ther e i s t oo muc h r el i anc e on mec hani c al gr eas er s and ot her aut omat i c l ubr i c at i ng dev i c es . Lubr i c at i ng s t andar ds ar e of t en nonex i s t ent or har dt o- f ol l ow.

Lubr i cat e. •

•

•

•

•

•

•

Teac h t he i mpor t anc e of l ubr i c at i on us i ng one- poi nt l es s on s heet s . Lubr i c at e i mmedi at el y whenev er y ou f i nd t hat equi pment i s i nadequat el y l ubr i c at ed or not l ubr i c at ed at al l . Repl ac e al l c ont ami nat ed l ubr i c ant s . Cl ean and r epai r al l di r t y or damaged l ubr i c ant and l ev el gauges . Chec k t o s ee whet her al l aut omat i c l ubr i c at i ng dev i c es ar e oper at i ng c or r ec t l y . Cl ean and l ubr i c at e al l r ev ol v i ng par t s , s l i di ng par t s , dr i v e c hai ns , and ot her mov i ng par t s . Cl ean and r epai r al l manual l ubr i c at i ng equi pment and l ubr i c ant c ont ai ner s .

Ti ght en.

•

Sec ur el y t i ght en l oos e nut s or bol t s .

•

Repl ac e mi s s i ng nut s and bol t s .

•

Repl ac e c r os s - t hr eaded nut s or bol t s t hat ar e t oo l ong.

•

Repl ac e damaged or s ev er el y wor n nut s and bol t s .

•

Repl ac e uns ui t abl e wi ng nut s and was her s .

•

Us e l oc k i ng dev i c es on i mpor t ant nut s per s i s t ent l y wor k l oos e.

Establish the Basic Equipment Conditions * Pr event i ng l i ne st op - Savi ng of $4, 800

Finding 113 troubles

* Count er measur es agai ns t ai r l eakage - Sav i ng of $10, 000/ year of l os ses Fi ndi ng 113 t r oubl es

Fi ndi ng ai r l eakage at 10 spot s

eat h g in s Feelhe pipe at t

Fi ndi ng 91 pr obl em s

* Repl aci ng t he mot or pump wi t h excess el ect r i c power wi t h a mor e sui t abl e mot or pump - Savi ng of el ect r i ci t y power cost

Checki ng poi nt s of bol t s and nut s

Pr oper f ast eni ng 1. 2.

3.

4.

I sn’ t t her e any l ooseness? Ar e t her e bol t s or nut s wher e t her e ar e hol es f or assembl y? I s a bol t i nser t ed f r om t he bot t om and f ast ened by a nut at t he t op? Ar e l engt hs of bol t s adequat e? ( 2 – 3 t hr eads above t he nut )

9.

I sn’ t t her e l ooseness of a l ocki ng nut of an adj ust i ng bol t ?

Pr event i on of l ooseness 1. 2.

3.

4.

Ar e washer s used f or l ong hol es? Ar e spr i ng washer s used t o t he nut s f or hol es whi ch ar e subj ect t o vi br at i on? Ar e t her e any pr event i on devi ces f or l ooseness t o t he nut s f or hol es whi ch ar e subj ect t o sever e vi br at i on? Ar e mParts atassembly ch section mar ks used f or cr i t i cal Leakage bol t s? Bad contact 1.

2.

3.

Looseness

Pr event i on of l ooseness Embedded bol t

1. Bol t l ooseness

1. Damaged gr oove Scr ew, bol t , et c

2. Damaged wr ench 3. Damaged scr ew t hr ead 4. Losseness 5. Washer , et c

Checki ng poi nt s of l ubr i cat i on

The l ubr i cat i on oi l management 1.

2.

3.

Ar e 3S of l ubr i cat i on oi l st ands OK? I s t her e appr opr i at e quant i t y of oi l needed t o l ubr i cat e? Ar e gr ease guns and oi l j ugs wel l mai nt ai ned?

Lubr i cat i on uni t s 1.

2.

3.

4.

5.

I s i t possi bl e t o check oi l quant i t y t hr u t he oi l l evel gauge ( posi t i on, t he degr ee of cont ami nat i on) ? Ar e t her e i ndi cat i on of t he upper and l ower l i mi t s of oi l quant i t y? Ar e t her e i ndi cat i on of t he upper and l ower l i mi t s of pr essur e on t he pr essur e gauge? I sn’ t t her e abnor mal noi se or over heat i ng i n pumps and mot or s? I sn’ t t her e oi l l eakage?

Lubr i cat i on syst em 1.

2.

3.

4.

Do aut omat i c gr easi ng uni t s and aut omat i c oi l i ng uni t s f unct i on pr oper l y? Do di st r i but i on val ves f unct i on r egul ar l y? Ar en’ t t her e any dust and di r t on t he ext er nal and i nt er nal sur f aces of an oi l er ? I s t he quant i t y OK? I sn’ t t her e an excess amount of gr ease or dust and di r t at gr ease ni ppl es?

5. Ar e t her e any damaged gr ease ni ppl es and cups? 6. I sn’ t t her e any cont ami nat i on due t o over - oi l i ng? 7. I s t her e pr oper oi l f i l m at sl i Grease di nipple ng sur f aces and r ol l er chai ns? 1.

Defective ball

2.

Deformation

3.

Cap

Grease cup 1.

Blockage

2.

Defective cap

Checki ng poi nt s of power t r ansmi ssi on Rol l er chai ns 1.

No wear or sl ack i n chai ns or spr ocket s?

2.

Ar e pi ns and cl i ps of connect i ng l i nks pr oper l y i nst al l ed?

3.

Ar e spr ocket s i nst al l ed pr oper l y?

4.

I s t he t ensi on of chai ns OK?

V bel t s 1. No scr at ches, br eakage, oi l cont ami nat i on or excessi ve wear ? 2. Ar e t ensi on of mul t i - bel t s const ant ? 3. No shi ni ng at t he bot t om of t he gr ooves of V pul l ey?

Bear i ng, coupl i ngs, keys 1.

No pl ay at t he bear i ngs, or no abnor mal noi se?

2.

Ar e axes of coupl i ngs par al l el ?

3.

No pl ay at keys and key gr ooves?

Mot or s, br akes, speed change gear s, el ect r omagnet i c cr ut ches 1. 2.

3.

4.

No over heat i ng, vi br at i on at mot or s? No abnor mal noi se, vi br at i ons at speed r educt i on gear s? No dust and di r t , damage on scal es or speed change handl es? No abnor mal noi se, vi br at i on at el ect r omagnet i c cl ut ches/ br akes?

5. No oi l cont ami nat i on, dust and di r t on t he l i ni ng pl at es? 6. No r ust on r ol l er chai ns? r ol l er chai ns dr y?

Ar en’ t

7. Ar en’ t t her e di f f i cul t ar eas t o l ubr i cat e?

Checki ng poi nt s f or pneumat i c/ hydr aul i c devi ces

Pneumat i c uni t s 1.

2.

3.

4.

Ar e ai r set s of t hr ee pi eces pr oper l y i nst al l ed so t hat t hey can be checked easi l y? No over heat i ng, abnor mal noi se i n el ect r o- magnet i c val ves? Ar e l ooseness pr event i on met hods appl i ed t o t he scr ews of cyl i nder r ods? No ai r l eakage?

Hydr aul i c uni t s 1.

2.

Ar e t her e i ndi cat i ons on t he oi l quant i t y gauge? Ar e t her e i ndi cat i on on t he oi l t emper at ur e gauge? I s t he t emper at ur e appr opr i at e?

3. Ar e t her e i ndi cat i ons on t he oi l pr essur e gauge? I s t he zer o poi nt cor r ect ? 4. No abnor mal noi se, over heat i ng, vi br at i on i n pumps?

5. Ar e l ocki ng nut s of r el i ef val ves / speed cont r ol l er s t i ght enough? 6. Ar e devi ces, pi pes pr oper l y i ns t al l ed? No oi l l eakage? 7. No abnor mal noi se, over heat i ng i n el ect r o- magnet i c v al v es?

Pi pi ng 1.

2.

3.

4.

No l ooseness i n pi pi ng and i t s cl ampi ng? No f r i ct i on of hoses of hi gh pr essur e? Ar e cyl i nder s i nst al l ed pr oper l y? Ar en’ t t hey i nst al l ed l oosel y? Ar e l ooseness pr event i on met hods appl i ed t o t he scr ews of cyl i nder r ods?

Checki ng poi nt s f or el ect r i ci t y Cont r ol panel s 1.

2.

3.

Ar e t her e i ndi cat i ons f or t he l i mi t s of vol t met er s and amper emet er s? Ar e t hei r val ues appr opr i at e? No def ect i ve name pl at es? l amps?

No br oken

Ar e door s t i ght l y cl osed? r edundant hol es?

Ar en’ t t her e

4. No dust and di r t i n cont r ol boxes? No unnecessar y i t ems i n t he boxes? 5. No abnor mal noi se i n r el ays?

El ect r i c devi ces 1.

2.

3.

4. 5.

Ar e LS’ s, phot o cel l s i nst al l ed pr oper l y? Ar e t he shapes of dogs of LS’ s cor r ect ? No cont ami nat i on by wat er / oi l t o LS, phot o cel l s and pr oxi mi t y swi t ches? No damage, pl ay i n devi ces? Do emer gency st oppi ng swi t ches f unct i on pr oper l y?

Wi r i ng/ cabl es 1. 2.

3.

No di sconnect i on of wi r i ng/ cabl i ng Ar e ear t hed l i nes pr oper l y i nst al l ed? Ar en’ t t her e excessi vel y l ong wi r es/ cabl es?

4. 11 4. 12 4. 4. 4. 4.

4.

St ep 2 Goal s f or Cont ami nat i on Sour ces and I naccessi bl e Pl aces 13 Pi npoi nt and El i mi nat e Sour ces of Leaks and Spi l l s 14 Fr om Compul sor y Det er i or at i on t o Nat ur al Det er i or at i on 15 Af t er I ni t i al Cl eani ng 16 Count er measur es agai nst t he Sour ces of Dust and Di r t and t he Di f f i cul t Ar eas t o Access 1) Removi ng 2) Bl ocki ng 3) Gui di ng 4) Usi ng l ocal i zed cover s 17 Sour ces of Dust and Di r t

St ep 2

St ep 2: El i mi nat e Sour ces of Cont ami nat i on and I naccessi bl e Pl aces

St ep 2: Addr ess cont ami nat i on sour ces and i naccessi bl e pl aces

Activities •

Reduce housekeepi ng el i mi nat i ng sour ces pr event i ng scat t er , par t s t hat ar e har d l ubr i cat e, t i ght en,

t i me by of dust and di r t , and i mpr ovi ng t o cl ean, check, or mani pul at e

St ep 2: Addr ess cont ami nat i on sour ces and i naccessi bl e pl aces

Hardware Goals (Keys for workplace audits) •

•

•

I ncr ease i nt r i nsi c equi pment r el i abi l i t y by pr event i ng adhesi on of dust and di r t and cont r ol l i ng t hem at t hei r sour ces I ncr ease mai nt ai nabi l i t y by i mpr ovi ng cl eani ng, checki ng, and l ubr i cat i ng Cr eat e equi pment t hat does not r equi r e manual wor k

St ep 2: Addr ess cont ami nat i on sour ces and i naccessi bl e pl aces

Human Goals (Keys for SGA audits) •

•

•

Teach t he phi l osophy and pr act i ce of equi pment i mpr ovement , st ar t i ng wi t h smal l - scal e, easi l y- accompl i shed pr oj ect s Ger mi nat e t he seeds of i mpr ovement i deas t hr ough smal l - gr oup act i vi t i es Let peopl e t ast e t he t hr i l l and sat i sf act i on of successf ul i mpr ovement

St ep 2: Addr ess cont ami nat i on sour ces and i naccessi bl e pl aces

Roles of Managers and Staff (fostering motivation, ability, and opportunity) •

•

•

•

Encour age i mpr ov ement i deas and gi ve pr ac t i c al hi nt s, i . e. , gi ve t ec hni cal gui danc e and suppor t Teac h pr obl em- sol vi ng t ec hni ques s uch as why- why anal y si s Ensur e t hat ot her depar t ment s r espond pr ompt l y t o wor k r equest s Gi ve gui dance on t he use of mat chmar k s and vi s ual cont r ol s

TABLE Dividing Step 2 into Sub Steps Subst ep

Maj or act i vi t y

1

Revi ew sour ce of cont ami nat i on.

2

Revi ew di f f i cul t cl eani ng ar eas.

3

Pr epar e t ent at i ve cl eani ng st andar ds.

4

Est i mat e cl eani ng i nt er val s.

5

Set cl eani ng t i me t ar get s.

6

Set i mpr ovement t ar get s.

7

Sour ce of cont ami nat i on:

7- 1

Conduct a why- why anal ysi s.

7- 2

Pl an r emedi al act i ons.

7- 3

Take r emedi al act i ons.

7- 4

Eval uat i on r esul t s of act i ons.

(-Continued)

8

Di f f i cul t cl eani ng ar eas:

8- 1

Conduct a why- why anal ysi s.

8- 2

Pl an r emedi al act i ons.

8- 3

Take r emedi al act i ons.

8- 4

Eval uat e r esul t of act i ons.

10

Revi se r esi dual i ssues.

11

Assess r esi dual i ssues.

12

Devel op a shor t r emedi al pr ogr am.

13

Conduct an aut onomous mai nt enance audi t .

STEP 2: Address contamination sources and inaccessible Step 2places : Countermeasures against

source of dust

Step 2

3. Improve AM work in difficult access areas 2. Prevent the existence of material pieces spread all over the machine

tep 2

1. Reduce sources of dirt

WORLD CLASS MANUFACTURING AUDIT Valladolid Plant, may 2008

IVECO PRODUCTION SYSTEM AUTONOMOUS MAINTENANCE

Goal s f or Cont ami nat i on Sour ces and I naccessi bl e Pl aces

Preventing Leaks and Spills Pr event l eaki ng, spi l l i ng, spr ayi ng, or scat t er i ng of : * pr oduct s * l ubr i cant s * hydr aul i c f l ui ds * powder s * vapor s * ot her pr ocess mat er i al s

I mpr ovi ng naccessi I mprIove accessibibil li it tyy of pl aces t hat ar e har d t o : * cl ean * check * l ubr i cat e * t i ght en * oper at e * adj us t

GOAL: Reduce t he t i me i t t akes t o cl ean, check, and l ubr i cat e

Pi npoi nt and El i mi nat e Sour ces of Leaks and Spi l l s •

•

•

•

•

•

•

Powder and vapor di schar ges make i t di f f i cul t t o mai nt ai n i ni t i al cl eani ng l evel s. Cont ami nat i on by dust and gr ease hamper s checki ng bol t s, nut s, oi l l evel gauges, and so on. Powder cont ami nat i on causes accel er at ed det er i or at i on, such as excessi ve wear of V- bel t s and dr i ve chai ns. Cont ami nat i on of l i mi t swi t ches, phot oswi t ches, and ot her sensor s causes mal f unct i on. Leaki ng l i qui ds and vapor s cause pr ocess uni t s, st ands, and ot her st r uct ur es t o cor r ode. I nf i l t r at i on of cont r ol panel s by powder s makes cont r ol unr el i abl e. Gener al cont ami nat i on i mpai r s t he wor ki ng envi r onment and l ower s pr oduct qual i t y.

Pi npoi nt and El i mi nat e Sour ces of Leaks and Spi l l s •

•

•

•

•

•

Fol l owi ng ar e key poi nt s f or r emedyi ng cont ami nat i on r esour ces: Accur at el y ascer t ai n t he nat ur e of t he cont ami nat i on and how and wher e i t i s gener at ed. Gat her quant i t at i ve dat a on t he vol ume of l eaks, spi l l s, and ot her cont ami nat i on ( t hi s hel ps oper at or s under st and t he i mpor t ance of measur ement ) . Encour age oper at or s t o t r ace cont ami nat i on back t o i t s or i gi nal sour ce ― bl ocks i n dust - col l ect i ng dust s and chut es, f or exampl e. Local i ze t he cont ami nat i on f i r st , t hen per si st ent l y r educe i t t hr ough a successi on of i mpr ovement s. Thi s pr oduces t he best r esul t s because one- shot i mpr ovement s ar e i mpossi bl e. Car r y out f ocused i mpr ovement s by pr oj ect t eams t hat i ncl ude manager s and t echni cal st af f . The pr oj ect t eam appr oach i s essent i al when deal i ng wi t h maj or cont ami nat i on sour ces t hat oper at or s cannot handl e t hr ough aut onomous mai nt enance. Consi der usi ng novel t echni ques and mat er i al s f or seal s, j oi nt s, pr ot ect i ve devi ces, and so on.

From Compulsory Deterioration to Natural Deterioration

1. Relationship between problems and compulsory deteriorat ion * Natural deterioration: Things deteriorate naturally as they are used properly. * Compulsory deterioration Things are deteriorated by outside force. The two sources of compulsory deterioration: * Equipment ... no prevention of causes of dust, dirt and sca ttering. * Operator ... unmaintained basic conditions such as clean ing, lubricating and bolting, human errors.

"Compulsory deterioration" caused by operator's improper act.

Take countermeasures at the source of problems by localization and change "compulsory deterioration" into "natural deterioration."

Af t er I ni t i al Cl eani ng

1.

Count er measur es t o sour ces of dust and di r t The met hods not t o gener at e t hem３ ( 1) Not t o gener at e t hem ( 2) Reduce t hei r quant i t y

2.

Count er measur es t o di f f i cul t ar eas t o access The met hods t o col l ect and r emove t hem３ ( 1) How t o col l ect t hem ( 2) How t o r emove t hem

Count er measur es t o Sour ces of Dust and t he Di f f i cul t Ar eas t o Access I ni t i al cl eani ng The sour ces of dust and di r t

The di f f i cul t ar eas To access

•

•

El i mi nat i on of t he sour ces of l eakage Local i zed dust col l ect or s

I nst al l at i on of t he cover s of pr ot ect i ng sc at t er i ng •

•

Bet t er means f or cl eani ng and l ubr i cat i on

•

Cent r al i zed l ubr i cat i on

•

I nst al l at i on of i nspect i on wi ndows

•

Neat l y ar r anged wi r i ng and pi pi ng

I mpr ovement Conf i r mat i on of ef f ect s

Sour ces of Dust and Di r t

factory Trouble due to foreign matter, dust, dirt, etc. The floor must be cleaned until no dirt can be detected on stroking with the palm of the hand or a white glove

watersoaked mat

wate r tray

Dust and dirt brought in by trolleys, movement of pallets, packing materials and machines, movement of people, ingress of outside air Scattering of sawdust, paper fibers, etc.

sweat from hands, etc.

Floor dust and dirt raised by cleaning, movement of people, and placing wire slings, containers, etc. on floor

Fig.

Dust falling from beams, crane hoists, vent pipes, etc. Splattering and dropping of oil, water, dirt, etc.

Contamination brought in on the work itself Contamination created by processing the work

Countermeasures: 1. 2. 3. 4. 5.

6.

Wax or paint floors Keep ceiling beams and cranes clean Provide wet mats at entrances Fit wheels with brushes or rags Ensure that interior of workshop is not at negative pressure Do not install large-capacity ventilation equipment unless absolutely necessary

brush grime collector

Fig. (Cont’d) Measures against sources of contamination in precision machine shops

attach brush or rag

grime collector

1. Removi ng Count er measur es agai nst dust by i nt r oduci ng cl eani ng br ushes Cl eani ng br ushes

Bel t conveyor Pr obl em : Bel t conveyor s get di r t y. Sol ut i on : I nst al l a bel t cl eaner t o mai nt ai n cl eanness of t he bel t conveyor . One poi nt l esson : pr ot ect i on cover .

I nst al l t he cl eaner i nsi de t he dust

Conveyor bel t

Mat er i al : har d sponge r ubber ( neopr ene)

Bel t cl eaner

Sponge r ubber Spr i ng

Sponge r ubber hol der

Count er measur e agai nst dust usi ng br ushes on bot h si des, Li f t i ng dust i n t he ai r and sucki ng i t by vacuum Paper dust el i mi nat or by usi ng br ushes f r om bot h si des

Count er measur es agai nst dust and easy r emoval of col l ect ed dust

1. St eel cover acr yl i c cover 2. Br ush t o t ake of f dust 3. Local i zed r emovabl e cover t o col l ect dust

Expl oi t oper at i onal movement f or cl eani ng at t he same t i me

Br ush Br us h

2)

Bl ocki ng

An openi ng f or a bear i ng by cut t i ng t he dust pr ot ect i on cover Pr obl em : Sol ut i on :

Dust and di r t wi l l come out f r om t he openi ng. Cover by magnet sheet .

Cover by st eel pl at e and cal ki ng mat er i al . One poi nt l esson : Use magnet i c sheet or st eel pl at e wi t h cal ki ng mat er i al so t hat t he bear i ng can easi l y be di smant l ed. An openi ng by cut t i ng t he dust pr ot ect i on cover

Cover t he openi ng by magnet i c sheet . Cover t he openi ng by st eel pl at e and cal ki ng mat er i al .

Pi t f or measur i ng i nst r ument Pr obl em : Sol ut i on :

Dust and di r t ar e accumul at ed i n a pi t . I nst al l r ubber sheet .

One poi nt l esson : Use ver y t hi n, l i ght and f l exi bl e r ubber sheet or vi nyl sheet f or dur abi l i t y. . Measur i ng t abl e

Rubber s heet

Tappi ng machi ne Pr obl em : Powder dr ops ont o t he pi t at t he t i me of f eedi ng powder i nt o a moul d. Sol ut i on : Pr event powder f r om f al l i ng t o t he pi t by pr ovi di ng t he moul d wi t h bel l ows.

Moul d Bel l ows

Tappi ng mac hi ne

3) Gui di ng Bel t conveyor Pr obl em : Ther e i s powder l eakage and dust gener at i on at t he di schar gi ng sect i on of a bel t conveyor . Sol ut i on :

I nst al l a dust pr ot ect i on cover .

One poi nt l esson : The cover shoul d be abl e t o be di smant l ed easi l y. For a smal l openi ng, use magnet i c sheet or pl ast i c sheet wi t h si l i con Dust pr ot ect i on cal ki ng mat er i al .

cover

Scat t er i ng pr ot ect i on cover

Chi p t r ay

Rubbi sh dr awer

Bel t conveyor Pr obl em : Ther e i s over f l ow of r aw mat er i al and powder l eakage t akes pl ace. Sol ut i on :

I nst al l a vi br at or t o r emove mat er i al .

One poi nt l esson : I n case of a smal l bel t conveyor , use an el ect r o- magnet i c f eed.

Di schar ge chut e

4) Usi ng l ocal i zed cover s No scattering any m ore !

It is im possible to clean,lubricate and inspect.

Use of localized cover

1. Is the supply of coolant concentrated on the cutting point correctly? 2. Grasp the direction, angle, quantity and speed of scattering. 3. Aren't there any problem s of operationability and safety?

•

Poi nt s I nvi ng ol scat v ed:t er i ng Pr event

of dust , et c. , at t he s our ce of t he pr obl em

du

• • •

Ex pec t ed Benef i t sr:onment I mpr oves envi I mpr oves qual i t y I ncr eases pr oduct i vi t y

st

I s t he cover f unct i oni ng as a dust r emover ? Reconst r uct ed so t hat dust i s sucked i n

Smal l Local i z ed Cover , Bi g Joy

Let's start by m aking a localcover "by hand."

Ki nds of Local i z at i on Cover s "Covering board type" low cost,easy to m ake.

"Box type" not m uch cost, big effects.・

・ Change the m aterial into plastic,rubber or steelplates.

Pr esent Condi t i on

heat f l ap

hi gh- t emper at ur e chamber

Obser vat i on:

door di f f usi on

Ent r ance t o hi gh- t emper at ur e el ect r i c f ur nace has a heat f l ap t o pr eser ve t he t emper at ur e wi t hi n t he chamber . As pr oduct s ent er t he el ect r i c f ur nace, however , t hey br ush agai nst t he f l ap and an excessi ve amount of heat st i l l escapes.

Af t er I mpr ovement

Af t er I mpr ovement s: Di f f usi on out si de t he f ur nace was r educed by i nst al l i ng a ser i es of 3 f l aps wi t h di f f er ent l engt hs.

es tiv fec De

Localization

g pin op St

ow ns d k a e r b ber of m u n e h T

Exampl e ( 1) : A l ocal i zed cover f or di sper si on of cut t i ng chi ps

( 1) Col l ec t i ng met hod of c hi ps

Dust col l ect i ng Dust col l ect i ng i nl et i nl et Cut t i ng Cut t i ng bl ade Vacuum pump Chi ps bl ade Bobbi n Bobbi n

Di sper si o n of cut t i ng chi ps Dust col l ect i ng box

Ther e i s a bi g space bet ween t he cut t i ng bl ade and t he cover

Dust col l ect i n g i nl et

Bobbi n chuck

Dust col l ect i ng i nl et

Pr obl ems Power of absor pt i on i s di sper sed

Chi ps ar e scat t er ed

( 2) Sur v ey on s c at t er i ng when t he dus t c ol l ec t i on c ov er i s not i ns t al l ed ( s hot by a hi gh- s peed v i deo c amer a) . Scat t er i ng ci r cl e gr aph area B

area B

area A area A

Scat t er i ng of chi ps f r om sect i on ⇒ 70% • Scat t er i ng of chi ps f r om t he r ot at i ng cut t i ng bl ade ⇒ 30% •

　 I t t ak es 20 mi n/ day t o c l ean t he s c at t er ed c hi ps j us t ar ound t he c ut t i ng s ec t i on, and 86 mi n/ day t o c l ean t he t ot al ar ea. • Thi s c l eani ng t i me i s t he bi gges t l os s i t em, and 54. 8% of al l non- v al ue added l os s t i me. • The t ot al l os t t i me due t o c l eani ng i s 1720 mi n/ mont h. •

( 3) Sur v ey on s c at t er i ng and c l eani ng t i me i n c as e of t he c onv ent i onal dus t c ol l ec t i on c ov er ( s hot by a hi gh s peed v i deo c amer a) ar ea B

Cut t i ng chi ps

Dust col l ect i ng i nl et

Bobbi n

Bobbi n chuck

Scat t er i ng ci r cl e gr aph ar ea B

Wi t hi n t he dust col l ec t i ng i nl et ar ea A

Wi t hi n t he dust col l ec t i ng i nl et

ar ea A

25% of t he act ual chi ps scat t er ed i s col l ect ed. • Chi ps comi ng out f r om t he cut t i ng sect i on ⇒ 40% ( ar ea A) • Di sper sed chi ps by cent r i f ugal f or ce ⇒ 30% ( ar ea B) • Ti me r equi r ed f or cl eani ng ar ound t he cut t i ng sect i on 20 mi n/ day •

(4) 1st improvement (improvement of the bobbin chuck and the change of the shape of the cover)

Shape of t he col l ect i ng i nl et ( f r ont ) Cut t i ng chi ps Cut t i ng bl ade

New col l ect i ng cover

New bobbi n chuck

Shape of t he col l ect i ng i nl et

1.

2.

I mpr ovement poi nt Space bet ween t he cut t i ng bl ade and t he cover → 　 minimum Space at t he bobbi n cut t i ng sect i on → 　 minimum (improvement of the chuck) Suct i on l oss • Less cut t i ng chi ps bei ng scat t er ed out of t he space. •

1.

2.

Lef t over pr obl ems Chi ps st i l l come out of t he space bet ween t he cut t i ng bl ade and t he cover . Chi ps whi ch st i ck t o t he bl ade wi l l scat t er by t he cent r i f ugal f or ce.

( 5) Conf i r mat i on of t he ef f ec t by t he 1s t i mpr ov ement Scat t er i ng ci r cl e gr aph Cut t i ng chi ps

ar ea B

ar ea B Cut t i ng bl ade

I nsi de t he col l ect i n g chi ps i nl et I nsi de t he col l ect i n g chi ps i nl et

I t i s possi bl e t o col l ect al l t he chi ps whi ch scat t er out of t he cut t i ng sect i on. • 20% of t he chi ps st i l l scat t er out by cent r i f ugal f or ce. •

Ti me r equi r ed f or cl eani ng ar ound t he cut t i ng sect i on •

:

3 mi n/ day

( 6) 2nd i mpr ov ement ( I mpr ov ement of t he s hape of t he c ov er and s et t i ng t he s auc er ) Shape of t he chi ps col l ect i ng i nl et ( f r ont )

New chi ps col l ect i ng cover

Saucer

Cut t i ng chi ps

I mpr ovement poi nt 1.

2.

Space bet ween t he cut t i ng bl ade and t he chi ps col l ect i ng cover →　 No space Scat t er ed chi ps →　 collected by saucer

Shape of t he i nl et

Chi ps col l ect i ng i nl et

Concent r at i on of sucki ng f or ce • Pr event i on of chi ps scat t er i ng •

( 7) Conf i r mat i on of t he ef f ec t by 2nd i mpr ov ement I nsi de t he saucer I nsi de t he chi ps col l ect i n g i nl et

Saucer

Scat t er i ng ci r cl e gr aph

Cut t i ng chi ps Chi ps col l ect i ng cover

I t has become possi bl e t o col l ect chi ps whi ch scat t er out of t he cut t i ng 　 　 section by centrifugal force. • The chips which have not been collected are gathered in a saucer. • Now it is scarcely necessary to clean the cutting section. •

Reduc t i on of t he amount ( and c l eani ng t i me) of c ut t i ng c hi ps at t he bobbi n c ut t i ng s ec t i on by t he i mpr ov ement of c hi p c ol l ec t i ng i nl et ( s hape, i nduc t i on ar ea) . BM Shape of t he chi p col l ect i ng iChi nl et p of lt ect he col icover ng i nl et ( i nduct i on Am ount of ar cut ea) t i ng chi ps ar ound t he cuteani t i ng Cl n sect g t i imon e ar ound t he cut t i ng sect i on

1st i mpr ovement

20. 9 cm 2

20 ３ 6 ３

20 mi n. / day

2 2. 0 cm

5. 8 ３

3 mi n. / day

2nd i mpr ovement

2 0. 8 cm

0 ３

0 mi n. / day

The f unct i ons of l ocal i zed cover s Name 1 Saf e ty

mechani s m

heat ant i expl osi o n

Funct i on

Not e

Equi pment → per s on

A per son i s pr ot ect ed agai nst t he i nj ur y. ( I f t he equi pment i s opened , an equi pment power suppl y and ai r suppl y wi l l st op aut omat i cal l y. )

Heat → per s on

I t pr ot ect s a per son f r om heat and bur ni ng.

Expl osi on →per s on

A per son i s pr ot ect ed agai nst t he expl osi on.

2

Soundpr oof i ng

Noi se → per s on

I t shut s of f t he noi se of t he equi pment .

3

Exhaust

Equi pment → envi r onment

I t l eads gas, st eam, col d ai r , war m ai r , and so on t o t he duct . ( hood)

4

Pr event i on of spl ash

Dust → equi pment

Di r t , dust , and so on ar e conf i ned. ( a l ocal cover )

5

Pr event i on of dr op

Equi pment → f or ei gn subst ance

Dr op of a par t and a pr oduct t o t he i nsi de of t he equi pment and t he f l oor i s pr event ed.

(cont i nued) Name

Funct i on

Not e

7

Pr ot ect i on of equi pment

Envi r onment → equi pment

Equi pment ar e pr ot ect ed agai ns t di r t , dust and s o on ( t he dust – pr oof , t he shi el d)

8

Pr event i on of i mpr oper oper at i on

Per son → equi pment

I f a c over i sn’t opened, a swi t ch can’t be oper at ed.

9

The oper at i on gui dance

Oper at i on i mpr ovement

Oper at i ng pr ocedur e i s s hown i n t he t r ans par enc y c over . ( t he i l l ust r at i on, t he number s)

1 0

The i nspect i on, di agnosi s f unct i on

Mai nt ai nabi lity i mpr ovement

A s t andar d f or i ns pec t i on and so on i s i ndi c at ed t o t he t r ans par enc y c over cl ear l y. ( bel t l oos eness l i mi t )

1 1

Appear ance

Appear ance

Unt i di nes s of wi r i ng and pi pi ng i nsi de t he equi pment i s hi dden.

1

Desi gn

Appear ance

Jus t f or good appear ance

Local i zat i on wi l l br i ng about … dust

dirt

Ican clear in a short tim e.

Localization

It is easy to lubricate and to inspect.

It is easy to do setup.

Prevention of scattering is im portant!

Further challenge ! Breakdowns and defectives have been reduced !!

I nspect i on t i me r educt i on

Measur e cl ocks i dent i f yi ng wi t h gr een and r ed zone

Wi ndows t o f aci l i t at e i nspect i on

Show f l ows di r ect i on and t ype of f l ui de i nsi de t he t ubes

Br eakdowns due t o l ack of basi c condi t i ons moni t or

MODEL AREA: No. of breakdowns / Machine stoppage hours

Breakdow ns due to lack of basic conditions STEP 1

25

STEP 2

7,53

20 5,07 5,2

5,07

15

4,99 3,58

10

2,3

5

2,78

Breakdowns due t o lack of basic conditions

Breakdowns t ime (hours)

WEEK 18

0 WEEK 17

0 WEEK 16

0 WEEK 15

0 WEEK 14

0 WEEK 13

WEEK 12

WEEK 11

0 WEEK 10

FEBRUARY

JANUARY

DECEMBER

NOVEMBER

OCTOBER

JULY

0

SEPTEMBER

1,12

8 7 6 5 4 3 2 1 0 0

B/ C Anal ysi s

Breakdow ns due to lack of basic conditions INSPECTION TIME REDUCTION

25

4 3,5

10

2,3

5

W 11

W 12

W 13

W 14

W 15

W 16

W17

W18

Breakdowns due to lack of basic conditions

B/C = 2,82

0

0

0

0

0

Breakdowns time (hours)

B/C = 33,67

WEEK 18

0

WEEK 17

FEBRUARY

W 10

JANUARY

0

DECEMBER

0,5

NOVEMBER

1

OCTOBER

1,12

0

SEPTEMBER

1,5

2,78

WEEK 16

2

WEEK 15

2,1

2

4,99 3,58

WEEK 14

2,15

5,07 5,2

WEEK 13

2,25

WEEK 12

2,35

2,5

5,07

15

2,6

WEEK 11

2,8

JULY

Average time

20

3

WEEK 10

3 3

7,53

8 7 6 5 4 3 2 1 0 0

AM standard

Team Working Method Activity

Responsible

Tag Classification and analysis

U.O. P.E., G.I. P.E., Maintenance leader, Team AM Leader Activity to transfer from PM to AM?

yes

Training to AM operators

Maintenance operator, AM operators

no Autonomous maintenance standard creation

U.O. P.E., G.I. P.E.,Maintenance operator, Team AM Leader , AM operators

AM Standard Scheduling

U.O. P.E., Leader Team AM

AM Standard check

U.O. P.E., Leader Team AM

AM Standard Samples

Color Code to identify different type of activity: Inspection Cleaning

Each activity explained with photo and instructions

4.18 Step 3 4.19 Establish Cleaning, Lubricating and Inspection Standard s 4.20 How to Reduce Time Required for Cleaning 4.21 How to Reduce Time Required for Inspection 4.22 How to Reduce Time Required for Lubricating 4.23 AM Calendar 4.24 How to Make Check Lists 4.25 Introduce Extensive Visual Controls 4.26 Step 4 4.27 Step 5 4.28 Step 6 4,29 Step 7

Step 3

St ep 3: Est abl i sh Cl eani ng, Lubr i cat i ng and I nspect i on St andar ds

Step 3: Establish Cleaning, Lubricating and Inspection Standards

Activities •

•

For mul at e wor k st andar ds t hat hel p mai nt ai n cl eani ng, l ubr i cat i ng, and t i ght eni ng l evel s wi t hi n mi ni mal t i me and ef f or t I mpr ove t he ef f i ci ency of checki ng wor k i nt r oduci ng vi sual cont r ol s

St ep 3: Est abl i sh Cl eani ng, Lubr i cat i ng and I nspect i on St andar ds

Hardware Goals (Keys for workplace audits) •

•

Sust ai n t he t hr ee basi c condi t i ons f or mai nt ai ni ng equi pment and pr event i ng det er i or at i on ( cl eani ng, l ubr i cat i ng, and t i ght eni ng) Per f or m accur at e checki ng by means of vi sual cont r ol s such as equi pment namepl at es and cor r ect oper at i ng r ange di spl ays on gauges

St ep 3: Est abl i sh Cl eani ng, Lubr i cat i ng and I nspect i on St andar ds

Human Goals (Keys for SGA audits) •

•

Ensur e t hat and l ear n t under st and i s) by havi

oper at or s hei r i mpor t what wor kpl ng t hem set

obey st andar ds ance ( i . e. , ace management t hei r own

Let peopl e l ear n t he i mpor t ance of t eamwor k by maki ng t hem awar e of t hei r i ndi vi dual r ol es

St ep 3: Est abl i sh Cl eani ng, Lubr i cat i ng and I nspect i on St andar ds

Roles of Managers and Staff (fostering motivation, ability, and opportunity) •

•

•

Gi ve hi nt s on wr i t i ng and pr esent i ng cl eani ng and i nspect i on st andar ds Gi ve t echni cal assi st ance i n pr epar i ng l ubr i cat i ng st andar ds Descr i be how vi sual cont r ol s can si mpl i f y checki ng, and gi ve pr act i cal advi ce

TABLE Driving Step 3 into Substeps

1.

2.

3.

4.

5.

Subst ep Maj or act i vi t y Conduct educat i on f or l ubr i cat i on. I dent i f y l ubr i cat i on poi nt s and sur f aces. Al l ocat e r out i ne l ubr i cat i ng t asks. Set t ent at i ve l ubr i cat i ng t asks. Est i mat e l ubr i cat i ng i nt er val s.

TABLE Driving Step 3 into Substeps (Cont’d)

6.

Subst ep Maj or act i vi t y Set l ubr i cat i ng t i me t ar get s.

7.

Set i mpr ovement t ar get s.

8.

Sour ces of cont ami nat i on: 1.

2. 3. 4.

I dent i f y l ubr i s our c es . Pl an r emedi al Tak e r emedi al Ev al uat e r es ul

c at i on r el at ed ac t i ons . ac t i ons . t s of ac t i ons .

TABLE Driving Step 3 into Substeps (Cont’d)

9.

Subst ep act i vi t y Equi pment def ect s: 1. 2.

Maj or

I dent i f y equi pment def ec t s . Res t or e equi pment def ec t s .

10. Di f f i cul t cl eani ng ar eas: 1. 2. 3. 4.

Conduc t a why - why anal y s i s . Pl an r emedi al ac t i ons . Tak e r emedi al ac t i ons . Ev al uat e r es ul t s of ac t i ons .

11. Revi ew l ubr i cat i ng st andar ds

TABLE Driving Step 3 into Substeps (Cont’d)

12.

13.

14. 15.

Subst ep Maj or act i vi t y Compar e wi t h l ubr i cat i ng st andar ds set by f ul l - t i me mai nt enance. Set cl eani ng and l ubr i cat i ng st andar ds. Devel op a shor t r emedi al pr ogr am. Conduct an aut onomous mai nt enance audi t .

Step 3: Establish Cleaning, Lubricating and Inspection Standards

Step 3 5. Perform accurate checking by means of visual controls 4. Sustain the three basic conditions for maintaining equipment and preventing deterioration (cleaning, lubricating, and inspection). 3. Give technical assistance in preparing lubricating standards

p3

2. Describe how visual controls can simplify checking, and give practical advice. 1. Establish Cleaning, Lubricating and Inspection Standards.

WORLD CLASS MANUFACTURING AUDIT Valladolid Plant, may 2008

IVECO PRODUCTION SYSTEM AUTONOMOUS MAINTENANCE

Establish Cleaning, Lubricating and Inspection Standards Let the operators establish what standards they m ust m aintain !

Topsds t andar efnev olo lmowed The down standar m adeds by ar staf are er hardf t aintain.

Est abl i sh Cl eani ng, Lubr i cat i ng and I nspect i on St andar ds

•

•

•

•

“ We’ ve been gi ven some st andar ds, but we don’ t r eal l y know why we have t o do t hese checks” “ We don’ t r eal l y under st and what we have t o check and how t o check i t . ” “ I f we t r y t o per f or m t he checks i n accor dance wi t h t he st andar ds, i t t akes f ar t oo l ong and we don’ t make any pr ogr ess. ” “ The checks ar e har d t o do because t her e ar e so many hi gh, cr amped or dar k pl aces. ”

Est abl i sh Cl eani ng, Lubr i cat i ng and I nspect i on St andar ds Sel f - s et s t andar ds ar e al way s obey ed.

Wi t h pr oper gui dance i n pr epar i ng st andar ds and est abl i shi ng checkpoi nt s, peopl e wi l l have t he mot i vat i on, abi l i t y, and oppor t uni t y t o f or mul at e r eal i st i c st andar ds f or pr event i ng det er i or at i on dur i ng t hei r dai l y checki ng.

I mpr ove accessi bi l i t y t o r educe wor ki ng t i me

Reduce cl eani ng t i mes. Reduce checki ng t i mes. I dent i f y har d- t o- l ubr i cat e pl aces. Si mpl i f y l ubr i cat i on t asks. Fol l ow a si mi l ar pr ocedur e f or equi pment t hat i s har d t o oper at e or adj ust .

Establishing Tentative Standards Quickly Decent r al i ze ⇒ Cent r al i ze ⇒ Si mpl i f i cat i on Sur el El i mi nat e mi ssi ng i t ems ⇒ y Det er mi ne checki ng pr ocedur es and sequences Easi l y under st and at a gl ance ⇒ Vi sual management and cont r ol Easi l y

Avoi d uncomf or t abl e post ur e ⇒ change spot s

How t o Reduce Ti me Requi r ed f or Cl eani ng

It takes so long to clean !

Limit supply of coolant and scattering in small areas. Take countermeasures in such a way that dust and dirt will not come into the are as that are hard to clean and lubricate. Move the important parts into the areas that remain clean.

How t o Reduce Ti me Requi r ed f or I nspect i on 1. Make t he hi dden i nspect i on spot r eveal ed.

Transparent acrylic board

* Num ber of belts * W ear,dust and dirt * Tension

2. Pl ace t he i nspect i on spot at t he hei ght of oper at or ' s 3. Meyes. ake t he hi dden par t s vi si bl e.

*Vibration *tem perature

Easy to inspect

It takes too m uch tim e to inspect

strainer strainer

How t o Reduce Ti me Requi r ed f or Lubr i cat i ng

Lubricate * with clean oilin right quantity * at the right charging spot * at scheduled tim e.

Oilis running short !

Breakdown

Im proper oilcharge

Too m uch is bad !

O il leakage Bad lubrication

Too low is also bad !

Seizing

Lubrication management : “4 lubrication principle s”

( 1)

( 2)

( 3)

( 4)

Check t he l ubr i cat i on oi l t ype and mi ni mi ze t he t ypes. Set appr opr i at e l ubr i cat i on cycl es. I mpr ove oi l char ge met hods. Check l ubr i cat i on quant i t y and set t he r i ght quant i t y.

( of sui t abl e oi l ) ( at r i ght t i me) ( by pr oper met hod) ( wi t h r i ght quant i t y)

There are too m any lubrication spots.

Autom atic lubricating system

To each lubrication spot

Cent r al i z ed oi l char gi ng

Two cent r al i zed l ubr i cat i on syst ems whi ch do not r equi r e t o st op t he machi ne.

Carrier guide

Distribution pipe Main pipe

Greasing pump

Distribution valve

Oi l Char ge- l ess From gear driven mechanism which requires lubrication

To belt driven mechanism which does not lubrication

Paper

Gear

Timing belt

Aut omat i on f or oi l char gi ng Oil charge

by hand

Automatic lubrication

frame

Operation side

Machine

* Bearing

Driving side frame

Gr easi ng bear i ngs f r om out si de

Greasing thru cupper pipes

AM Cal endar I mpl ement per i odi c aut onomous mai nt enanc e, moni t or r es ul t s and r ev i ew – i nt r oduc e aut onomous mai nt enanc e c al endar . I nspect i on i t ems. Key poi nt s. Met hod. Tool s. Ti mes. I nt er val s. Responsi bi l i t y.

3. 3

Fi gur e : Cl eani ng and Lubr i cat i on St andar ds ( Tokai Rubber I ndust r i es)

No.24

Expiration date:12/81

Friction gear O illevel

Cleaning and lubricating standards for 3-S/RL No. 1

Cleaning areas Category Around m ain fram e

2

M ain body and surroundings

3

Oilwindow

4

Oilsupply pum p and distribution valves Inside roller pit

5

Cleaning check points Lubricating areas Letter

Category

a

Lubricator

b

Friction gears

c

Large gearwheel

d

Autom atic oilsupply pum p (for drive shaft and m etal parts ofrollers)

Lubrication checkpoints

Plant m anager: Section chief: PM engineer: Forem an:

Cleaning and lubricating standards for 3-S/RL Cleaning standards

Cleaning m ethods

Cleaning equipm ent

Raw m aterials plant Cleaning tim e

Rem ove with steel scraper;sweep up

No scattering of rubber scrap

Sweep away with broom

5 m in.

O illeveleasy to check

W ipe clean with cotton waste

3 m in.

No oiland dirt

W ipe clean with cotton waste

10 m in.

Day W k. M o.

○

No rubber scrap adhering to fram e

Cleaning cycle

15 m in.

○ ○ ○ ○

Not leaking or dirty

30 m in.

1.Tighten the autom atic supply pum p ring joint bolts 2.Tighten oilsupply valve and check for leaks 3.Tighten the stock guide fixing bolts

Lubrication standards

Lubrication m ethods

Lubrication Lubrication Lubrication cycle tools tim e Day W k. M o.

Pour by hand

O illevelhalf-way up gear teeth (#32)

O ilcan

5 m in.

Gearwheelwell-lubricated (open gearwheel)

Drip in through oilsupply port with spatula

5 m in.

Adequate oil(as m easured by the oilgauge)(R50)

Use oil applicator

3 m in.

○

O illevelm ust be between upper and lowerlim it (#220)

10 m in.

○ ○ ○ ○○

1.Secure large gearwheelcover (no rattling) 2.Secure attachm ent bolts for autom atic oilsupply pum p

○

3.Check 3-unit FRL and drip rate

Sampl e I nspect i on Checkl i st s Li mi t Swi t ch

Oi l Pr essur e Pump

Check I t ems

Check I t ems

1. Cor r ect st op posi t i on

1. Di schar ge pr essur e set cor r ect l y

2. Cor r ect l i mi t swi t ch posi t i on

2. Cor r ect amount of oi l i n t ank

3. No pl ay i n pi n

3. St r ai ner not cl ogged by debr i s

4. Rol l er on t r ack, no sl i ppage

4. Cl ean hydr aul i c oi l , no ai r bubbl es

5. No debr i s obst r uct i ng movi ng par t s

5. Cor r ect coupl i ng

6. Vol t age and cur r ent wi t hi n r at ed val ues

6. Pump and mot or axes pr oper l y cent er ed

7. Lever mot i on wi t hi n l i mi t val ues

7. No noi se, over heat i ng, or vi br at i on i n pump

8. No l i qui d or vapor on swi t ch

8. No noi se, over heat i ng, or vi br at i on i n mot or

　　　　　　　　　　 　　　　　　　　　 - 　　　　　 　　　　　　 　　　　　　　　　 Check I t ems

I nspect i on Resul t s

Check I t ems

I nspect i on Resul t s

1. Cor r ect Posi t i on st op nor mal posi t i on

OK

5. No debr i s on movi ng par t s

None

2.

Posi t i on nor mal

OK

6. Vol t age and cur r ent wi t hi n r at ed val ues

Rat ed: OK AC 200 V 2A Act ual : 198 V 1. 2A

3. No pl ay i n pi n

No pl ay

OK

7. Lever mot i on wi t hi n l i mi t val ues

St andar d: wi t hi n 90° Act ual : wi t hi n 60°

OK

4. Rol l er on t r ack, no

On t r ack

OK

8. No l i qui d or vapor on

Some cool ant on swi t ch, but i t ’ s

✔

Cor r ect l i mi t swi t ch posi t i on

OK

　　　　　　　　　　 　　　　　　　　　 - Mal f unc t i oni ng Oi l Pr es s ur e Pump Check Items

Inspection Results

Check Items

Inspection Results

1. Discharge pressure set correctly?

standard: 20±2 kg/cm2 actual: 20.5 kg/cm2

OK

5. Coupling normal?

Yes

OK

2. Normal Within level amount of range oil in tank?

OK

6. Pump and motor axes cantered?

standard ≤ 1mm off center actual: .08mm off center

OK

3. Strainer free of debris?

very clogged

✔

7. Noise, a lot of noise, overheatin overheating, g, or and vibration vibration in pump?

✔

4. Hydraulic oil clean, no air bubbles?

very dirty, also cloudy

✔

8. Noise, No overheatin g, or vibration in motor?

OK

How t o Make Check Li st s * Keep the daily inspection precisely by check lists. W hat and when to check.

Have allthe item s been listed within the allowable checking tim e?

* Check item s are in the order ofactualoperation. At the start of work

M ainly lubrication inspection

During operation

Inspection by hum an sense

At the end of work

M ainly cleaning inspection

I nt r oduce Ext ensi ve Vi sual Cont r ol s •

•

•

•

•

•

•

Mar k each i t em of equi pment wi t h i t s name and number t o make ever yone awar e of i mpor t ant uni t s. Put mat chmar ks on nut s and bol t s t o si mpl i f y checki ng f or sl ackness. I ndi cat e accept ant r anges on i nst r ument s, such as pr essur e gauges, vacuum gauges, t her momet er s, and ammet er s t o f aci l i t at e cor r ect oper at i on. I ndi cat e l ubr i cant l evel s, t ypes, and quant i t i es t o i mpr ove mai nt ai nabi l i t y. Label coupl i speci f checki

t he cover s of devi ces such as V- bel t s, chai ns, and ngs wi t h t hei r r ot at i on di r ect i on and i cat i ons t o i mpr ove mai nt ai nabi l i t y and si mpl i f y ng.

Label pi pes wi t h t hei r f l ow di r ect i on and cont ent s t o i mpr ove mai nt ai nabi l i t y, oper abi l i t y, and saf et y. Pr ovi de on/ of f i ndi cat i ons on val ves and swi t ched t o i mpr ove mai nt ai nabi l i t y, oper abi l i t y, and saf et y.

Wi r e mesh

Fi gur e.

I ndi cat e Bel t Si ze on Saf et y Cover

.

Exam Lubr i cat i o pl n i nl et di spl ay col or coded by t ype of l ubr i cant

e of bear i ng l ubr i cat keep i on Al ways

I ndi cat es number of l ubr i cat i on poi nt s

bear i ng

Vi sual cont r ol s f or oi l gauges

gr een

or ange

Col or s may be used f or oi l l evel cont r ol

r ed

Vi sual Cont r ol s f or Lubr i cat i on

gr ease ni ppl es cl ean and f i t caps Nowher bl ock e ed pi pes possi bl e Us e t r anspar ent pi pi ng or cl ean Ver i f y shaf t annual l ubrl i ycant suppl y by checki ng f or l eaks ar ound l ubr i cat ed par t s r ed gr een Fl oat : l i qui d l evel made vi si bl e f r om out si de

Cl ean spool s Cl ean gui de r ol l er s

Cl ean di es and ni ppl es • •

Cl ean i nt er i or of wat er bat hs

Cl ean pr i nt r ol l er s, kni ves, et c.

Keep ar ea wi t hi n 20 cm of pr oduct spot l ess Tr y t o r educe cont ami nat i on caused by f al l i ng dust

Fi gur e.

Cont act - Goods Fi ve S’ s f or Ext r usi on Li ne

Pi pi ng check st r ai ner

I ndi cat e per son r esponsi bl e on mai n val ves t o be cl osed on shut down days

Use r ever si bl e t her mosensi t i ve l abel t o i ndi cat e t emper at ur e

gauge mar k ( gr een)

Per son Keep f l ow di r ect i on r espons I dent i f y open i bl e f l ui d usi ng dur i ng f or JI S col or oper at mai n code i on val ve I ndi cat e whet her val ve i s t o be kept open or cl osed

Di spl ay of r epl acement dat e on el ect r i cal par t s ( l i mi t swi t ches, r el ays, et c. )

Col or - codi ng of r ecept acl es f or t r ash, r ecycl abl e wast e, fetl am c.mabl e ３

３

nonf l ammabl e Exampl e: bel showi ng r epl acement dat e Combust i bl e mat er i al - whi t e l et t er s on gr een backgr ound e. Exampl e of Vi sual Cont r olI ncom s bust i bl e mat er i al -

Di spl ay of easi l y mi st aken pr essi ng sequence f or but t ons

I ndi cat e sequence i n bl ac

Appl i cat i on: t o di spl ay st ar t i ng sequence To i ndi c at e or der i n whi ch swi t c hes , but t ons, et c. ar e t o be oper at ed when I ndi sequence st ar tciatnge equi pment i n r ed Appl i cat i on: t o di spl ay sequence f st oppi ng equi pment To i ndi cat e or der whi ch swi t ches, but t ons, et c. ar e be oper at ed when t ur ni ng equi pment Appl i cat i on: i nspect i on dat st i cker Recor d schedul i nspect i on dat af f i x t o par t

or in to of f

e ed e and t o be

Gauge mar k s

Sl ackness l i mi t Di spl ay bel t si ze

gr een ( nor mal val ue) r ed ( saf et y l i mi t )

er t i on of

B- 80×3

I nst al l i n pumps , v al v es, bear i ngs , mot or s, eset cI. ns pec t i on dat es t her mocoupl

P

sl ackne ss l i mi t

Check f or sl i ppage usi ng t her mosensi t i ve l abel

Col or - codi ng el ect r i cal set t i n

Li ght i ng mapMai

gr een r ed

I nt er i or

Fi gur e

Make i t easy t o t el l whet her t he t her mocoupl e i s f ul l y i nser t ed

10/ 87 12/ 87

n swi t ch

Dat e f or cl eani ng and i nspect i ng el ement . Ar e mi cr on- si zed f or ei gn par t i cl es bei ng t r apped? Ar e you not onl y Ni ght - onl y l i ght i ng: gr een cl eani ng, but al so Ni ght + cl oud: yel l ow checki ng how much Ni ght + r ai n: r ed and what ki nd of

Per son in geo Maichar n Pr - t enanc e

duc tio n

Vol t age Dest i nat i on

st i cker

.

Hydr aul i c uni t s Pai nt ar ea ar ound ai r br eat her s i n whi t e, and al ways keep cl ean

The f our mai n enemi es of hydr aul i c f l ui d 1.

Check f or damage and di r t on pi st on hy dr aul i c c yl i nder

2.

3.

i ndi cat i on of use sol enoi d val ve

I ndi cat e oi 4.l condi t i on i nspect i on dat e f i l t er t her mome t er

oi l - l evel gauge

Exampl e of Gener al I nspect i on I t ems

Ai r ent r ai nment - no f r ot hi ng. For ei gn mat t er ( wat er , dust , f or ei gn f l ui ds) - cl ean ai r br eat her s, check f i l t er s, t ake car e when changi ng f l ui d, i nspect and cl ean f l ui d, et c. Hi gh t emper at ur e - t emper at ur e shoul d be bel ow 55 ℃. Al so be car ef ul about di f f er ences i n i nl et and out l et f l ui d t emper at ur es i n heat exchanger s. Leaks ai nt dam ai n age packit ong hiand Sur- f m ace ghpr event vi breat hoses i on. pr essur and

wi r i ng.

Check f or scr at ches, cr acks, di r t , et c.

Vi sual i zat i on f or t he checki ng r out e

capst an

r eal i gnment r ol l er

gui de r ol l er gui de r ol l er

pi pe

pr essur e r ol l er

count er

gui d e r ol l er

gui de r ol l er c ont r o capst an l c aps tpanel an pr essur e r ol l er Bobbi n wi nder t ur nt abl e

gui de f el t pad

Suppl y

br ak e c- spool

Make a habi t of doi ng t he best dr awi ng pos si bl e

No.

Item

Phenomenon Method

1

C-spools

Dirt and surface damage

2

Felt pads

Copper or iron powder

3

Guide and realignment rollers

Faulty rotation

Touch

Check for anything Scratchthat es feels unusual

Look

Limit sample

Look

Check Scratchthat es, faulty 14 × 5 mark is winding rotating

Quantify so far as possible. If not possible, check parts using limit samples.

Figure

Standar Effect on Type of Department Recurrence Number Interval d quality control responsible prevention

　

Clarify relation between defect and equipment.

Cleaning and Inspection Standard

All

―

When return- Production ing

5

―

Once a day

　

―

Once a day

　

Need for accuracy trend control, etc. It is important to indicate the number to be checked.

I nt er val Dai l y

Mont h 1

Mont h 2

Mont h 3

Ti me r equi r ed Appr ox. 10 mi n.

Ever y 10 days

15- 20 mi n.

Mont hl y

15- 20 mi n.

Ever y 3 mont hs

15- 20 mi n.

e

Equipment name

No.

Maintenance item

1 FRLs

Check oil level, drain, disassemble and service

Lubrication of 2 grease nipples 3 Rust

No. of sites

7

Day 1

2

3

●

4

30

31

Person responsible

Robinson

25

　

Paint, apply corrosion inhibitor

―

Compressed air, gas, water, oil

―

Cont ami nat ed i n t wo pl aces 　

―

　

12

　

4

Leakage (draw maps)

5

Scatter (draw Chips, dust, fumes maps)

6 Sight-glasses Oil level, oil contamination

Autonomous Maintenance Calendar

●

　

Aut onomous mai nt enance cal endar CI L

STEP 3. AM Cal endar

TYPE OF ACTIVITY ACCORDING TO SUPPLIER’S PROCEDURE

COMPONENT

STANDARD CODE

STEP 3. AM Standard Examples STABILIMENTO: VALLADOLID

STABILIMENTO: VALLADOLID

U.O. CARROCERÍAS

U.O. CARROCERÍAS

MÁQUINA: OP20A MASCHERONE

MÁQUINA: OP20A MASCHERONE

CÓDIGO CICLO:

CÓDIGO CICLO:

T. CICLO: OP20A_1_2

INSPECCIÓN

LIMPIEZA

LUBR

T. CICLO: OP20A_1_4

ESTANDAR CODIFICACIÓN COLORES /FRECUENCIA

INSPECCIÓN

LIMPIEZA

LUBR

ZONAS DE LUBRICACIÓN DE MESA OP20A

OP 20A BALANCINAS Y MESA DE RODILLOS

COLOUR CODE: OIL / GREASE TYPE RED

GREEN

BLUE

YELLOW

ORANGE

COLOR

SHELL LAMORA 320

KLUBER SYNTHESO D460 EP

KLUBER ISOFLEX NBU 15

KLUBERSYNTH GH6-220

LOCTITE 8101

DESCRIPTION

CC 320

CC 460

-------

220

-------

ISO

75319506

75319506

75261824

-------

75258328

SAP

SQ22RB SQ21RB SQ24RB SQ23RB

0 SQ37RB 0 SQ38RB

SQ26RB

0 0 SQ25RB

MOT VAR DX

O.S. DX

SQ28RB

0 0 SQ27RB

SHAPE CODE : FREQUENCY

SQ30RB

0 WEEKLY

MONTHLY

BIMONTHLY

QUARTERLY

SIX-MONTHLY

0

0 0 SQ29RB

C4

ANNUAL

C3

SQ32RB

0 0 SQ31RB M.ELEV.

RETROCESO

POS

0 O.SEG2

RETR.

0

0 O.SEG3

AV.

0

RAL STOP

0 0 CENTR. STOP RAL

M.R.

POS

0S

0 E. ALTO 0 E. INTERM.

0B

E. BAJO

0 O.SEG1

AVANCE

0 0 SQ11RB C2

C1 0

0

SQ12RB

0 0 SQ9RB

OP20A EN REPOSO

SQ10RB

0 0 SQ7RB O.S. SX

0 SQ18RB 0 SQ17RB

LABOR ULTIMADA

SQ8RB

MOT VAR SX

0 0 SQ5RB

ANOMALIA OP20A

SQ6RB SQ3RB

WIP OP20A

SQ4RB SQ1RB SQ2RB

DURACIÓN DEL CICLO

FRECUENCIA

MATERIAL DE CONSUMO HERRAMIENTAS NECESARIAS

DURACIÓN DEL CICLO 180 minutos

WORLD CLASS MANUFACTURING AUDIT Valladolid Plant, may 2008

FRECUENCIA 1 veces cada 2 meses

MATERIAL DE CONSUMO HERRAMIENTAS NECESARIAS Líquido lubricante

IVECO PRODUCTION SYSTEM AUTONOMOUS MAINTENANCE

STEP 3. Vi sual Management

STEP 3. Vi sual Management

STANDARDIZATION OF THE CIL TASK LIST BEFORE

Over time due to single 3° step task list without optimization

AFTER

Optimization of the CIL task list

30 min/week 　 -31% vs actual

AM STATUS AND FUTURE VISION Restore Basic Condition

Become a human sensor

Expand responsibilities

Management by objectives

Machine 4 P

C

D

Machine 1

Machine 3

Machine 2 People Development

A

TODAY

OUR VISION TOMORROW

Step 1-3: results

Costs and Benefits Step 1-3 3000,0 2500,0

2752 2279

2221

2000,0

1686

1684

Costi

1500,0

Benefici

1000,0

583 500,0 0,0

Step 1

Step 2

Step 3

Step 1-3: results N° of bre akdow ns due to the la ck of ba sic conditions

Cleaning and Inspection Time 800 700

20 Minuti/settimana

600

10

4

Step 2

600

00

Attività a macchina ferma Totale attività

500 400

419

300

280

200 117,88

100

3

0

Step 1

740

Obj=125 min/sett

36

0

1° STEP 2° STEP 3° STEP 4° STEP 5° STEP

Step 3

Scraps / Step AM Ta gs 400 350 286

300 238

250 200 150 100

143

Step 1

Step 2

Step 3

2,00 1,80 1,60 1,40 1,20 1,00 0,80 0,60 0,40 0,20 0,00

0,40

Step 1

0,42

Step 2

0,38

Step 3

Step 1-3: results

Step 3

Step 4

1° INPUT: Residual losses Total machine losses: Rettifica De Clichy (TG745389)

2° INPUT: People motivation

22% losse lo s

OEE Perdite totali

78%

15%

LOSSES TO ATTACK WITH AM PILLAR Scraps and reworks Maintenance activities

Introduction of new inspections

After the implementation of the first three steps team members have expressed the desire to improve their skills through training activities focused on the main machine operating groups.

Step 4

St ep 4: Per f or m Gener al Equi pment I nspect i on

Step 4: Conduct general equipment inspection

Activities •

•

•

Pr ovi de i nspect i on ski l l s t r ai ni ng based on i nspect i on manual s Get i ndi vi dual equi pment i t ems i nt o peak condi t i on by subj ect i ng t hem t o gener al i nspect i on Modi f y equi pment t o f aci l i t at e checki ng. Make ext ensi ve use of vi sual cont r ol s

St ep 4: Conduct pment i nspect Hardware Goals gener (Keysalforequi workplace audits)i on •

•

I mpr ove r el i abi gener al i nspect det er i or at i on f cat egor y ( nut s syst ems, et c. )

l i t y by i on and or each and bol t

per f or mi ng r ever si ng equi pment s, dr i ve

Enabl e anyone t o i nspect r el i abl y by i nt r oduci ng vi sual cont r ol s such as equi pment namepl at es, V- bel t speci f i cat i on di spl ays, l ubr i cant t ype and quant i t y di spl ays, cor r ect oper at i ng r ange pl ays on gauges, val ve on–of f i ndi cat or s, r ot at i on di r ect i on i ndi cat or s, t her mochr omi c

St ep 4: Conduct gener al equi pment i nspect i on

Human Goals (Keys for SGA audits)

•

•

•

•

Lear n equi pment st r uct ur e, f unct i ons, and assessment cr i t er i a and mast er checki ng ski l l s t hr ough hands- on checki ng t r ai ni ng Lear n t o deal wi t h equi pment abnor mal i t i es t hr ough on- t he- spot pr act i ce Use r el ay t eachi ng t o enabl e l eader s t o l ear n l eader shi p and member s t o devel op t eam spi r i t Let peopl e under st and t he usef ul ness of dat a by col l ect i ng gener al

St ep of 4:Managers Conduct gener al equi pment i motivation, nspect i on Roles and Staff (fostering ability, and opportunity)

Pr epar e gener al i nspect i on and t r oubl eshoot i ng case st udi es, and t r ai n gr oup l eader s i n i nspect i on ski l l s • Dr aw up i nspect i on schedul es • Gi ve on- t he- spot t r ai ni ng i n si mpl e met hods of r ect i f yi ng abnor mal i t i es • Pr ompt l y per f or m wor k r equest ed as a r esul t of exposi ng abnor mal i t i es • Gi ve gui dance i n i mpr ovi ng vi sual cont r ol s • Gi ve i nst r uct i on i n dat a col l ect i on and anal ysi s • I nvol ve gr oup l eader s i n mai nt enance •

TABLE Driving Step 4 into Substeps Subst ep act i vi t y 1. Educat i on: 1. 2. 3.

2.

Maj or

Conduc t gener al educ at i on. Conduc t s pec i f i c educ at i on. Conduc t a c ompr ehens i v e t es t .

I nspect i ve i t ems: •

•

Pr epar e i ns pec t i ng c hec k l i st s. As s es s i ns pec t i v e i t ems .

3. I nspect i ve: •

•

Conduc t an ov er al l i ns pec t i on. Remedy def ec t i v e ar eas di s c ov er ed.

TABLE Driving Step 4 into Substeps (Cont’d) Subst ep Maj or act i vi t y 4. Set t ent at i ve i nspect i ng st andar ds. 5.

Est i mat e i nspect i ng i nt er val s.

6.

Set i nspect i ng t i me t ar get s.

7.

Set i mpr ovement t ar get s.

8.

Di f f i cul t i nspect i on ar ea: •

•

I dent i f y di f f i c ul t i ns pec t i ng ar eas . Remedy di f f i c ul t i ns pec t i ng ar eas .

TABLE Driving Step 4 into Substeps (Cont’d)

9.

Subst ep Maj or act i vi t y Revi ew i nspect i ng t asks.

10.

Al l ocat e r out i ne i nspect i ng ski l l .

11.

Check oper at or s’ i nspect i ng ski l l .

12.

Devel op a shor t r emedi al pr ogr am.

13.

Conduct an aut onomous mai nt enance audi t .

How t o car r y out gener al i nspect i on

1.Basic knowledge of equipm ent * How far knowledge is necessary? (Clarification ofthe range ofknowledge)

2.Training / Education * How m uch have the operators understood? (Confirm ation test)

3.Visualm anagem ent * Easy to inspect * Easy to find abnorm alities

Devel opi ng equi pment - compet ent oper at or s

Devel opi ng equi pment - compet ent oper at or s r evol ut i oni zes not j ust equi pment but ever y ot her aspect of wor kpl ace management as wel l .

Pr epar i ng f or gener al i nspect i on t r ai ni ng Sel ect gener al i nspect i on i t ems. Pr epar e mat er i al s f or gener al i nspect i on t r ai ni ng. Dr af t gener al i nspect i on t r ai ni ng schedul e.

1.

2.

3.

4.

Mai nt enance st af f i nst r uct t eam l eader s. Team l eader s pass on t hei r knowl edge t o t eam member s ( r el ay t eachi ng) . Oper at or s per f or m gener al i nspect i on. An audi t i s hel d and t he t eam st andar di zes, or consol i dat es i nspect i on pr ocedur es.

Pr ocedur e f or devel opi ng gener al i nspect i on t r ai ni ng pr ogr am Est abl i sh gener al i nspect i on cat egor i es Mai nt enance st af f Pr epar Pr epar e t r ai ni ng mat er i al s e Mai nt enance st af f Schedul e t r ai ni ng Mai nt enance st af f and wor kpl ace super vi sor s

( e. g. , Nut s, bol t s, l ubr i cat i on sys t ems, pneumat i c s, hydr aul i c s, dr i v e s yst ems , el ec t r i cs, et c. )

Checks heet s Manual s ( Cut away model s, wal l char t s, s l i des, et c. )

Tr ai n gr oup l eader s Mai nt enance st af f Tr aiPr n epar e f or “r el ay t eachi ng” of gr oup member s Gr oup l eader s; wor kpl ace super vi sor s Tr ai n gr oup member s Gr oup l eader s

( Gener al i ns pec t i on of model equi pment )

Pr ocedur e f or devel opi ng gener al i nspect i on t r ai ni ng pr ogr am Conduc t gener al i nspect i on

( Gener al i ns pec t i on of al l equi pment )

Gr oup member s Gener al Hol d gr oup meet i ngs, l i s t I nspect abnor mal i t i es, pl an act i ons i on Gr oup l eader s Cor r ect abnor mal i t i es Gr oup member s; mai nt enance per sonnel Est abl i sh pr ovi s i onal dai l y i ns pec t i on s t andar ds Gr oup member s Assess i nspect i on ski l l s Gener al I nspect i on Gr oup member s Rei nf or cem e f or m s el f - audi t and appl y Per nt f or of f i ci al audi t

Abnor mal i t i es l i st s ( Det er i or at ed par t s; i naccessi bl e ar eas)

Pr ovi si onal st andar ds ( On compl et i on of each cat egor y) Ski l l s ass ess ment c har t s ( Pr act i cal t est s)

Gr oup l eader s Per f or m audi t Wor k pl ace Move t o nest i nspect i on super vi sor s; cat egor y ( appr oxi mat el y one mai nt enance st af f cat egor y per mont h) Tr eat pr obl em ar eas i ndi cat ed Gr oup member s; mai nt enance per sonnel

Sampl e schedul e f or mat f or gener al i nspect i on t r ai ni ng Cat egor y Nut s and bol t s

Lubrication

Transmission s

Pneumatics

Mont h 1

Mont h 2

① 　　　② 　　　　　　 ③ 　　　　　　　　　　④ ① 　　　② 　　　　　　③ 　　　　　　　　　　④

Mont h 3

Mont h 4

①Fr om mai nt enance st af f t o gr oup l eader s ②Fr om gr oup l eader s t o gr oup member s ③Gener al equi pment i nspect i on ④Rei nf or cement of gener al i nspect i on cat egor y ① 　　　② 　　　　　　③ 　　　　　　　　　　④ ① 　　　② 　　　　　　 ③ 　　　　　　　　　　④

I mpl ement i ng gener al i nspect i on t r ai ni ng

The i mpor t ance of “ r el ay t eachi ng. ” Tr ai ni ng t eam l eader s. Pr epar at i on by t eam l eader s. Rel ay t eachi ng i n pr act i ce. Conduct i ng t he gener al equi pment i nspect i on. Consol i dat i on af t er each gener al i nspect i on.

TPM Pr epar at i on

Teach

TPM Depl oyment

Teach

Pi l ot Team

Manager ’ s Model Teams e. The depl oyment of TPM act i on t eams

Equi pment Act i on Teams

Gener al i nspect i on of bol t s and nut s

Don’ t f ast en bol t s/ nut s t oo t i ght ! I f t i ght ened t oo muc h, bol t s eas i l y get br ok en.

Do not i nser t bol t s f r om t he t op!

Ov er l ook t he l oos ened nut .

The l ac k of t he nut c annot be f ound.

Do not use t hi nner nut s above t hi cker nut s! Thi s i s t o t i ght t he bol t . Upper nut

Bol t Body Thi s i s not t o move t he upper nut .

Gener al i nspect i on of l ubr i cat i on

Do not i ndi cat e t he pr essur e gauge l i mi t s t he gl ass cover !

Fr ont gl ass

Never l et t he pr essur e gauge needl e r each t h l r i ght - hand posi t i on!

Do not l eave smal l oi l l eakage ! By f i ndi ng causes, we wi l l be abl e t o i ncr ease t he mai nt enance l evel .

Gener al i nspect i on of hydr aul i c/ pneumat i c devi ces

Concr et e exampl e of i nspect i on ３ Hydr aul i c ３ Uni t ( 1)

Chec k wi t h “ ey es ” 　 Ar e hy dr aul i c uni t s not c ont ami nat ed by c hi ps and c ut t i ng oi l ? 　 I s n’ t t her e any oi l l eak age f r om pumps , el ec t r omagnet i c v al ues or j oi nt s ? 　 Ar e pr es s ur e gauges pr oper ones ? 　 Does i t k eep a r i ght v al ue? 　 Ar e t he t y pes and c apac i t i es of t he pump and t he mot or appr opr i at e? 　 I s t he oi l l ev el gauge c l ear ? 　 Ar e t he quant i t y and t he c ol or of oi l pr oper ? 　 I s t he c ap of t he oi l s uppl y out l et c l os ed pr oper l y ? 　 Ar e t her e any s pac es or hol es i n t he mai n body of t he t ank , f r om whi c h dus t may c ome i n? 　 I s n’ t t he l eak ed oi l r et ur ned t o t he t ank ?

( 2)

( 4)

( 6)

Chec k wi t h “ ear s ” 　 Ar e t her e any r oar i ng s ounds pr oduc ed f r om pumps , mot or s , t he el ec t r o- magnet i c v al ues or pi pes ? Chec k wi t h “ hand” by t ouc hi ng s ur f ac es 　 I s t her e any v i br at i on or gener at ed heat f r om pumps , mot or s or el ec t r o- magnet i c v al v es ? 　 Ar e t he l oc k i ng nut s of pumps , mot or s or el ec t r omagnet i c v al v es not l oos ened? 　 Chec k oi l l eak age by wi pi ng t he ar ea. 　 Ar e t he pi pes i nt er s ec t ed or c ont ac t ed wi t h eac h ot her ? Chec k by r emov i ng 　 How i s t he wear of c upl i ngs of mot or s and pumps ? 　 Ar e t he ai r br eat her s of oi l s uppl y out l et c aps appr opr i at e? 　 Ar e t he oi l s t r ai ner s of oi l s uppl y out l et s not t or n

Do not t wi st hoses ! When t her e i s t wi st , a punct ur e t akes pl ace.

No t wi st

Do not use hoses i n a st r et ched st at e!

Fl exi bl e

Do not bend hydr aul i c hoses t oo much!

o not br i ng oi l t emper at ur e above 60 degr ees hydr aul i c t ank !

Need a cool er Ri ght zone Need at t ent i on at t he t i me of st ar t up

Gener al i nspect i on of power t r ansmi ssi on

Do not al l ow a chai n t o be sl acki ng mor e t ha % of t he di st ance bet ween t he t wo axes !

The di st ance

Dr i vi ng si de

Concr et e exampl e of i nspect i on : Dr i vi ng Uni t s ( 1) Chec k wi t h “ ey es ” 　 Ar e t he mot or s and r educ t i on gear s not c ont ami nat ed by c hi ps and oi l ? 　 Ar e bel t s not l oos ened? I s t he t ens i on nor mal ? 　 Ar e t he oi l l ev el gauges of r educ t i on gear s c l ean? 　 I s i t eas y t o c hec k bel t s or t he pul l ey s ? ( 3) Chec k wi t h “ ear s ” 　 Ar e t her e any r oar i ng s ounds or s l i ppi ng s ounds pr oduc ed f r om mot or s , r educ t i on gear s , bel t s or c hai ns ? ( 5) Chec k wi t h “ hand” by t ouc hi ng dur i ng oper at i on 　 I s t her e any v i br at i on or gener at ed heat f r om mot or s or r educ t i on gear s ? ( 7) Chec k by s t oppi ng t he oper at i on or by t ouc hi ng wi t h hand 　 Ar e t he quant i t y and t he c ol or of oi l of r educ t i on gear s pr oper ? 　 Ar e s af et y c ov er s pr oper l y equi pped? 　 Ar e bol t s of mot or s and r educ t i on gear s not

　 Chec k by r emov i ng I s bel t t ens i on pr oper ? Ar e t he t y pes and t he number of bel t s and pul l ey s pr oper ? Ar e bel t s and pul l ey s not wor n? Ar e bol t s and k ey s of pul l ey s not l oos ened? Ar e bel t s bet ween pul l ey s s t abl e? Ar e mot or s and r educ t i on gear s c onnec t ed pr oper l y ? Ar e t he c upl i ngs bet ween a mot or and a r educ t i on gear not wo Ar en’ t mot or s and ai r c ool i ng f ans c l ogged wi t h dus t ? I s t her e dus t i n t he l ubr i c at i on oi l of r educ t i on gear s ?

Do not di r ect st oppi ng cl i ps of a chai n t owar ds t he r ot at i ng di r ect i on !

Movi ng di r ect i on

Do not al l ow a chai n t o j ump over a t oot h of a spr ocket !

New Wor n

Do not gr ease chai ns, use oi l !

Rol l er

Pi n Bush

Char ge oi l t o a chai n at t he l oosened si de.

Oi l

Dr i vi ng si de

Do not use V bel t s i n t he si t uat i ons of ②, ③ and ④ i n t he f i gur e!

For ei gn Wor n body pul l ey

Wor n bel t

Do not change one bel t onl y! Repl ace al l t he bel t s at t he same t i me!

Do not al l ow V bel t s t o vi br at e l at er al l y ! When bear i ngs ar e hot , bel t t ensi on i s t oo hi gh. t he pul l eys ar e hot , bel t t ensi on i s t oo l ow.

Sl i ps t ake pl ace.

The causes of l at er al vi br at i on : •

Eccent r i ci t y

•

Wear

•

Looseness

When

Gener al i nspect i on of el ect r i ci t y

Do not over l ook r educed pr essur e of an ai r set of t hr ee uni t s !

Do not put t he l ower l i mi t of t he oi l er bel ow t he hei ght of t he suct i on pi pe!

Mi st In

Ai r pr essur e Suct i on pi pe

Do not l eave ai r l eakage of an ai r set t hr ee uni t s ! Ai r l eakage t akes pl ace at t he f ol l owi ng poi nt s : 1.

Joi nt bet ween t he uni t s

2.

Ai r r el i ef hol e of a pr essur e r educt i on val ve

3.

Gasket of t he case

4.

Damaged case

5.

Damaged gauge gl ass

6.

Oi l char ge pl ug of t heGaske oi l er

Sc r ew

Si ght gl ass Oi l pl ug Out Gaske tCase

t

Cas e

Dr ai n l ock

Rel i ef hol e

Gauge gl ass

( 1) . Checkpoi nt s f or nut s and bol t s

Sl i ght Def ect s

• Ar e any nut s or bol t s l oose? • Ar e any nut s and bol t s mi ssi ng?

Bol t Lengt hs

• Do al l bol t s pr ot r ude f r om nut s by 2- 3 t hr ead l engt hs?

Washer s

• Ar e f l at washer s used on l ong hol es? • Ar e t aper ed washer s used on angl e bar s and channel s? • Ar e spr i ng washer s used wher e par t s ar e subj ect t o vi br at i on? • Ar e i dent i cal washer s used on i dent i cal par t s?

At t achment of Nut s and Bol t s

• Ar e bol t s i nser t ed f r om bel ow, and ar e nut s vi si bl e f r om t he out si de? • Ar e devi ces such as l i mi t swi t ches secur ed by at l east t wo bol t s? • Ar e wi ng nut s on t he r i ght way ar ound?

( 2) . Lubr i cat i on checkpoi nt s

Lubr i cant St or age • Ar e l ubr i cant st or es al ways kept cl ean, t i dy, and wel l - or gani zed by t hor ough appl i cat i on of t he 5S pr i nci pl es? • Ar e l ubr i cant cont ai ner s al ways capped? • Ar e l ubr i cant t ypes cl ear l y i ndi cat ed and i s pr oper st ock cont r ol pr act i ced? Lubr i cant I nl et s

• Ar e gr ease ni ppl es, speed- r educer l ubr i cant por t s, and ot her l ubr i cant i nl et s al ways kept cl ean? • Ar e l ubr i cant i nl et s dust pr oof ed? • Ar e l ubr i cant i nl et s l abel ed wi t h t he cor r ect t ype and quant i t y of l ubr i cant ?

( 2) . Lubr i cat i on checkpoi nt s

Oi l - l evel Gauges

• Ar e oi l - l evel gauges and l ubr i cat or s al ways kept cl ean, and ar e oi l l evel s easy t o see? • I s t he cor r ect oi l l evel cl ear l y mar ked? • I s equi pment f r ee oi l l eaks, and ar e oi l pi pes and br eat her s unobst r uct ed?

Aut omat i c Lubr i cat i ng Devi ces

• Ar e aut omat i c l ubr i cat i ng devi ces oper at i ng cor r ect l y and suppl yi ng t he r i ght amount of l ubr i cant ? • Ar e any oi l or gr ease pi pes bl ocked, cr ushed or spl i t ?

Lubr i cat i on Condi t i on

• Ar e r ot at i ng par t s, sl i di ng par t s, and t r ansmi ssi ons ( e. g. chai ns) al ways cl ean and wel l - oi l ed? • Ar e t he sur r oundi ngs f r ee of cont ami nat i on by excess l ubr i cant ?

( 3) . Tr ansmi ssi on syst em checkpoi nt s

V- bel t s and Pul l eys

• Ar e any bel t s cr acked, swol l en, wor n, or cont ami nat ed by oi l or gr ease? • Ar e any bel t s t wi st ed or mi ssi ng? • Ar e any bel t s st r et ched or sl ack? • Ar e mul t i pl e bel t s under uni f or m t ensi on and al l of t he same t ype? • Ar e t op sur f aces of bel t s pr ot r udi ng above t he pul l ey r i ms? Ar e t he bot t oms of any pul l ey gr ooves shi ny ( i ndi cat i ng a wor n bel t or pul l ey) ? • Ar e pul l eys cor r ect l y al i gned?

Rol l er Chai ns

• Ar e any chai ns st r et ched ( i ndi cat i ng wor n pi ns or bushi ngs) ? • Ar e any spr ocket t eet h wor n, mi ssi ng, or damaged? • I s l ubr i cat i on bet ween pi ns and bushi ngs suf f i ci ent ? • Ar e spr ocket s cor r ect l y al i gned?

( 3) . Tr ansmi ssi on syst em checkpoi nt s

Shaf t s ３ Bear i n gs ３ and Coupl i ngs

• I s t her e any over heat i ng, vi br at i on, or abnor mal noi se due t o excessi ve pl ay or poor l ubr i cat i on? • Ar e any keys or set bol t s l oose or mi ssi ng? • Ar e any coupl i ng mi sal i gned or wobbl y? • Ar e any coupl i ng seal s wor n? Ar e any bol t s sl ack?

Gear s

• Ar e gear s pr oper l y l ubr i cat ed wi t h t he r i ght amount of l ubr i cant ? Ar e t he sur r oundi ngs cl ean? • Ar e any t eet h wor n, mi ssi ng, damaged, or j ammed? • I s t her e any unusual noi se or vi br at i on?

( ３ ) . Hydr aul i c checkpoi nt s

Hydr aul i c Uni t s

• I s t he cor r ect quant i t y of f l ui d i n hydr aul i c r eser voi r s, and i s t he cor r ect l evel i ndi cat ed? • I s f l ui d at t he cor r ect t emper at ur e? Ar e t he maxi mum and mi ni mum per mi ssi bl e t emper at ur es i ndi cat ed? • I s f l ui d cl oudy ( i ndi cat i ng ai r ent r ai nment ) ? • Ar e al l f l ui d i nl et s and st r ai ner s cl ean? • Ar e any suct i on f i l t er s bl ocked? • Ar e any f l ui d r eser voi r br eat her f i l t er s bl ocked? • Ar e al l f l ui d pumps oper at i ng nor mal l y wi t hout any unusual noi se or vi br at i on? • Ar e hydr aul i c pr essur es cor r ect , and ar e oper at i ng r anges cl ear l y di spl ayed?

Heat Exchanger s

• I s any f l ui d or wat er l eaki ng f r om f l ui d cool er s or pi pes? • Ar e t emper at ur e di f f er ences bet ween f l ui d and wat er i nl et s and out l et s cor r ect ? Ar e any

( ３ ) . Hydr aul i c checkpoi nt s

Hydr aul i c Equi pment

• Ar e t her e any f l ui d l eaks? • Ar e hydr aul i c devi ces pr oper l y secur ed wi t hout any makeshi f t f ast eni ngs? • Ar e hydr aul i c devi ces oper at i ng cor r ect l y wi t hout speed l osses or br eat hi ng? • Ar e hydr aul i c pr essur es cor r ect , and ar e al l pr essur e gauges wor ki ng cor r ect l y ( zer o poi nt s, def l ect i on) ?

Pi pi ng and Wi r i ng

• Ar e al l pi pes and hoses secur el y at t ached? • Ar e t her e any f l ui d l eaks? Ar e any hoses cr acked or damaged? • Ar e al l val ves oper at i ng cor r ect l y? I t i s easy t o see whet her val ves ar e open or shut ? • Ar e any pi pes, wi r es, or val ves unnecessar y?

( 5) . Pneumat i c checkpoi nt s

FRLs

• Ar e FRLs al ways kept cl ean? I s i t easy t o see i nsi de t hem? Ar e t hey f i t t ed t he r i ght way ar ound? • I s t her e suf f i ci ent oi l , and ar e t he dr ai ns cl ear ? • I s t he oi l dr i p r at e cor r ect ( appr oxi mat el y 1 dr op f or ever y 10 st r okes) ? • Ar e FRLs i nst al l ed no mor e t han 3 m f r om t he pneumat i c equi pment ? • Ar e pr essur es adj ust ed t o t he cor r ect val ue and ar e oper at i ng r anges cl ear l y i ndi cat ed?

( 5) . Pneumat i c checkpoi nt s Pneumat i c Equi pment

• I s any compr essed ai r l eaki ng f r om pneumat i c cyl i nder s or sol enoi d val ves? • Ar e al l pneumat i c cyl i nder s and sol enoi d val ves f i r ml y at t ached? • Ar e any makeshi f t f i xi ngs i n use ( wi r e, adhesi ve t ape, et c. ) ? • Ar e any pi st ons di r t y, wor n, or damaged? • Ar e speed cont r ol l er s i nst al l ed t he r i ght way ar ound? • I s t her e any abnor mal noi se or over heat i ng of sol enoi d val ves, and ar e any l ead wi r es chaf ed or t r ai l i ng?

Pi pi ng and Wi r i ng

• Ar e t her e any pl aces i n pneumat i c pi pes hoses wher e f l ui d i s l i abl e t o col l ect ? • Ar e al l pi pes and hoses cl i pped f i r ml y i pl ace? • Ar e t her e any compr essed- ai r l eaks? Ar e hoses cr acked or damaged? • Ar e al l val ves oper at i ng cor r ect l y? I s i easy t o see whet her val ves ar e open or

or nt o any t

( 6) . El ect r i cal checkpoi nt s

Cont r ol Panel s • Ar e t he i nt er i or s of di st r i but i on boar ds, swi t chboar ds, and cont r ol panel s kept cl ean, t i dy and wel l - or gani zed by t he appl i cat i on of t he 5S pr i nci pl es? Have any ext r aneous obj ect s or f l ammabl e mat er i al s been l ef t i nsi de? • I s t he wi r i ng i nsi de cont r ol panel s i n good condi t i on? Ar e any wi r es coi l ed or r ai l i ng? • Ar e al l ammet er s and vol t met er s oper at i ng cor r ect l y and cl ear l y mar ked? • Ar e any i nst r ument s or di spl ay l amps br oken? Ar e any bul bs f aul t y? • Ar e any swi t ches br oken? Do al l swi t ches wor k cor r ect l y? • Ar e cont r ol panel door s i n good condi t i on? Do t hey open and cl ose easi l y? • Ar e t her e any unused hol es? Ar e cont r ol panel s wat er pr oof and dust pr oof ?

( 6) . El ect r i cal checkpoi nt s

El ect r i cal Equi pment

• Ar e al l mot vi br at i on, • Ar e al l mot • Ar e any at t pedest al s f

or s f r ee of over heat i ng, and unusual noi se and smel l s? or cool i ng f ans and f i ns cl ean? achment bol t s l oose? Ar e r ee of cr acks and ot her damage?

Sensor s

• Ar e al l l i mi t swi t ches cl ean and f r ee of excessi ve pl ay? • Ar e t he i nt er i or s of al l l i mi t swi t ches cl ean? Ar e any wi r es t r ai l i ng? Ar e al l cover s i n good condi t i on? • Ar e any l i mi t swi t ches i ncor r ect l y i nst al l ed? • Ar e any l i mi t swi t ch dogs wor n, def or med, or t he wr ong shape? • Ar e al l phot oel ect r i c swi t ches and pr oxi mi t y swi t ches cl ean and f r ee of excessi ve pl ay? • Ar e any sensor s out of posi t i on? Ar e cor r ect posi t i ons cl ear l y i ndi cat ed?

( 6) . El ect r i cal checkpoi nt s

Swi t ches

• Ar e al l manual s swi t ches cl ean, undamaged, and f r ee of excessi ve pl ay? • Ar e al l swi t ches i nst al l ed i n t he cor r ect posi t i on? • Ar e emer gency st op swi t ches i nst al l ed i n appr opr i at e l ocat i ons, and ar e t hey wor ki ng cor r ect l y?

Pi pi ng and Wi r i ng

• Ar e any pi pes, wi r es, or power l eads l oose or unsecur ed? • Ar e any gr ound wi r es damaged or di sconnect ed? • Ar e any pi pes cor r oded or damaged? Ar e t her e any bar e wi r es or wi r es wi t h damaged i nsul at i on? • Ar e any wi r e coi l ed on t he f l oor or dangl i ng over head?

( 7) . Checkpoi nt s f or gener al - pur pose equi pment

Pump s

• Ar e pumps and t hei r st ands f r ee of unusual noi se, vi br at i on, and pl ay? • Ar e pedest al bol t s t i ght , cor r osi on- f r ee, and undamaged? • Ar e st ands and pedest al s f r ee of cor r osi on, cr acki ng and ot her damage? • I s any l i qui d l eaki ng or spr ayi ng f r om gl and packi ngs? • I s any l i qui d l eaki ng or spr ayi ng f r om pi pes or val ves? • Ar e any pi pes or val ves bl ocked? • Ar e al l pr essur e gauges, vacuum gauges, f l owmet er s, t her momet er s, and ot her measur i ng i nst r ument s wor ki ng pr oper l y and mar ked wi t h t he cor r ect oper at i ng r anges? • Ar e st ar t i ng cur r ent and oper at i ng cur r ent val ves cor r ect ? Ar e t hese cl ear l y i ndi cat ed? • Ar e al l val ves oper at i ng cor r ect l y? I s i t easy t o see whet her whet her val ves ar e open or cl osed?

( 7) . Checkpoi nt s f or gener al - pur pose equi pment

Fans

• Ar e f ans and t hei r st ands f r ee of unusual noi se, vi br at i on, and pl ay? • Ar e al l pedest al bol t s t i ght , cor r osi on- f r ee, and undamaged? • Ar e al l st ands and pedest al s f r ee of cor r osi on, cr acki ng, and ot her damage? • Ar e any gl and packi ngs l eaki ng ai r or gas? • Ar e any dust s or damper s l eaki ng ai r or gas? • Ar e any dust s bl ocked or cl ogged? • Ar e al l pr essur e gauges, vacuum gauges, f l owmet er s, t her momet er s, and ot her measur i ng i nst r ument s wor ki ng pr oper l y and mar ked wi t h t he cor r ect oper at i ng r anges? • Ar e st ar t i ng cur r ent and oper at i ng cur r ent val ues cor r ect ? Ar e t hese cl ear l y i ndi cat ed? • Ar e al l damper s oper at i ng cor r ect l y? I s i t easy t o see whet her damper s ar e opened or cl osed?

Step 4: General Inspection Step 4 Costs and Benefits Evaluation 3000

2400 2426,69

2500 2000

1500 1561,38

Costi

1500

Benefici

1000 500 0 1

Costs Inspection and cleaning activities Training - Losses in productivity

Benefits Further reduction of losses (scraps) and consequent increase of OEE Reduction of inspection activities made by professional maintenance team

317

Step 4: General Inspection Machine decomposition Operating groups Inspection cards

OPL

Training room

Practical Training 9 trained people 27 total training hours

318

Step 0. Basic training: Operators’ Knowledge and Skills - example

TRAINING

INITIAL STATE

.1 .2 .3 .4 .5 .6 .7

M a n t e nim ie n t o M e cá n ico M a n t e nim ie n t o Elé ct r ico M a n t e nim ie n t o N e u m á t ico Act ividades a ut on om a s W CM H e r r a m ie nt a s de Ca lida d Logist ica

a ct ua l

PI LARES

re que rido

CURRENT STATE

2 2 2 3 3 3 2

2 2 2 3 3 3 2

WORLD CLASS MANUFACTURING AUDIT Valladolid Plant, may 2008

1

requerido actual

319 IVECO PRODUCTION SYSTEM AUTONOMOUS MAINTENANCE

Example of training efficiency COMPONENT: PROXIMITY BEFORE

AFTER

Monthly substitution of the component following to collisions for wrong assembly

COMPONENT COST: 37 € 450 €

Correct assembly Component substitution at the end of its life-cycle

Annual substitution costs PX 407 €

400 € 350 € 300 € 250 € 200 € 150 € 100 €

37

50 € -€ Step 1-3

Step 4

320

Step 4: General Inspection Quality Correlation Matrix

Component Inspections Quality Inspections From product control to process control

Safety Inspections

Heinrich Pyramid New unsafe act and conditions identified

2006

2007

FATALITY Fatality

0

0

LWDC > 3 DAYS

0

0

LWDC ≤ 3 DAYS

0

0

FAI

0

0

NEAR MISSES

0

0

UNSAFE ACTS AND CONDITIONS

1

5

321

Step 4: General Inspection

Usura punta da contatto per mancata lubrificazione Controllo bloccaggio della contropunta mediante manometro

Quality inspections allowed to identify abnormalities on equipment.

322

Step 4: results Cleaning and Inspection Time

Costs and Benefits / Step 2752

800

2279

2221 2000

1684

Costi Benefici

1419 583

€

1000

1686

0

Step 1

Step 2

Step 3

700

2022

Step 4

Minuti/settimana

3000

740 600

600 500

419

400

Attività a macchina ferma Totale attività

280

300

192,81

200

117,88

100

36

Obj=210 min/sett

59,19

0 1° STEP 2° STEP 3° STEP 4° STEP 5° STEP

STEP

Scraps / steps 2,00 1,80 1,60 1,40 1,20 1,00 0,80 0,60 0,40 0,20 0,00

AM Tags 400 350 286

300 238

250

0,40

0,42

0,38

0,26

200 150

Step 1

Step 2

Step 3

Step 4

302

143

100

Step 1

Step 2

Step 3

Step 4

Step 4: results

Step 4

Step 5 Total machine losses: Rettifica De Clichy (TG745389)

15,5%

OEE Perdite totali

84,5%

5%

LOSSES TO ATTACK WITH AM PILLAR

Maintenance activities

Reduction of cleaning and inspection times

324

Sep 5

St ep 5: Per f or m Gener al Pr ocess I nspect i on

St ep 5: Per f or m gener al pr ocess i nspect i on

Activities •

•

Pr ovi de i nst r uct i on i n pr ocess per f or mance, oper at i on, and adj ust ment and i n met hods of handi ng abnor mal i t i es i n or der t o i mpr ove oper at i onal r el i abi l i t y by devel opi ng pr ocess- compet ent oper at or s Pr event i nspect i on dupl i cat i ons and omi ssi ons by i ncor por at i ng pr ovi si onal cl eani ng and i nspect i on st andar ds f or i ndi vi dual equi pment i t ems i nt o per i odi c i nspect i on and r epl acement st andar ds f or ent i r e

St ep 5: Per f or m gener al pr ocess i nspect i on

Hardware Goals (Keys for workplace audits) •

•

•

I mpr ove t he over al l st abi l i t y and saf et y of pr ocess t hr ough cor r ect oper at i on Shar pen pr ocess i nspect i on pr eci si on by ext endi ng and i mpr ovi ng vi sual cont r ol s, e. g. , i ndi cat or s f or pi pe cont ent s and f l ow di r ect i ons Modi f y equi pment t o make i t easi er t o oper at e

St ep 5: Per f or m gener al pr ocess i nspect i on

Human Goals (Keys for SGA audits) •

•

•

•

Enabl e oper at or s t o oper at e pr ocesses and deal wi t h abnor mal i t i es cor r ect l y Enabl e oper at or s t o under st and t he r el at i onshi p bet ween equi pment and t he pr oper t i es of t he mat er i al s bei ng pr ocessed and mast er t he cor r ect adj ust ment and set t i ng t echni ques Make oper at or s awar e of t hei r r ol es i n pl anned mai nt enance and f ost er sel f - management t hr ough per i odi c i nspect i on and r epl acement Hel p oper at or s r eal i ze t he necessi t y

St ep 5: Per f or m gener al pr ocess i nspect i on

Roles of Managers and Staff (fostering motivation, ability, and opportunity) •

•

•

•

Prepare general process inspection manuals and troubleshooting manuals, and train group leaders in inspection skills Provide on-the-job training in the correct adjustment and setting procedures Give guidance on selecting periodic inspection and replacement items, techniques, and documentation, and give instruction on setting appropriate intervals based on hard data Prevent planned maintenance duplications and omissions by clearly delineating the operating and maintenance departments’ responsibilities

TABLE Driving Step 5 into Substeps Subst ep Maj or act i vi t y 1. Revi ew r esi dual i ssues l ef t f r om St eps 1 t hr ough 2. Pr obl ems: I dent i f y pr obl ems i n c l eani ng. l ubr i c at i ng s t andar ds s et i n s t ep 3 and c at egor i c al i ns pec t i ng s t andar dsand s et m ii nnor St ep 4. 3. Br eakdowns Pl an Ex ami ne c aus es . st1. oppages: 2. r emedi al ac t i ons . 3. Tak e r emedi al ac t i ons . 4. Ev al uat e r es ul t s of ac t i ons . 1.

TABLE Driving Step 5 into Substeps (Cont’d) Subst ep act i vi t y 4. I nspect i on 1.

2.

3. 4.

5.

Maj or

Set t ent at i v e r out i ne i ns pec t i ng s t andar ds . Compar e wi t h mai nt enanc e s t andar ds s et by f ul l - t i me mai nt enanc e. Set i ns pec t i ng t i me t ar get s . Set t ent at i v e r out i ne i ns pec t i ng s c hedul es . Conduc t r out i ne i ns pec t i on.

5. Revi ew cl eani ng, l ubr i cat i ng/ i nspect i ng st andar ds

TABLE Driving Step 5 into Substeps (Cont’d) Subst ep act i vi t y

Maj or

6. Set aut onomous mai nt enance st andar ds and schedul es. 7. Devel op a shor t r emedi al pr ogr am. 8. Conduct an aut onomous mai nt enance audi t .

What i s t he r ol e of gener al pr ocess i nspect i on Aut onomous i nspect i on Structuraldrawing

Lubrication system

This is the m ost im portant check point !

Breakdowns can be avoided ifyou check this point.

Ifthe check point is wellknown. Right inspection can be carried out !

Equipm ent can be restored by the periodic repair !

What i s t he r ol e of aut onomous i nspect i on?

Gener al pr ocess i nspect i on ⇒ Make usabl e st andar ds

Pr ocedur e f or devel opi ng t he pr ocess i nspect i on t r ai ni ng pr ogr am

St ep 5- 1: Cor r ect oper at i on and mani pul at i on. St ep 5- 2: Cor r ect adj ust ment and set t i ng. St ep 5- 3: Cor r ect handi ng of abnor mal i t i es.

Pr ocedur e f or i mpl ement i ng gener al pr ocess i nspect i on St ep 5- 1 St ep 5- 2 St ep 5- 3 Pr epar e oper at i on manual s

Pr epar e per f or mance and f unct i on l essons

Rel ay Rel ay OJT t eachi ng St af f St af f gr oup l eader sgr oup l eader sgr oup member s gr oup member s

Rei nf or ce ( pr act i cal t est s)

Rei nf or ce ( i ndi vi dual t est s)

Cor r ect oper at i on and mani pul at i on

I dent i f y adj ust ment and set t i ng keys

Pr epar e adj ust ment / set t i ng manual s

Rel ay OJT St af f gr oup l eader sgr oup member s

Rei nf or ce ( pr act i cal t est s)

Est abl i sh Cl ar i f y cur r i cul um uni t s I dent i f y l i kel y r esponsi bi l i t y f or f or chemi cal sour ce of per i odi c checks engi neer i ng ser i ous acci dent s and par t s basi cs r epl acement

Pr epar e l esson sheet s

Rel ay St gr oup gr oup

t eachi ng af f l eader smember s

Rei nf or ce ( i ndi vi dual t est s)

Cor r ect adj ust ment and set t i ng

Pr epar e over haul Pr epar e manual s checki ng and on abnor mal si gns par t s r epl acement and phenomena manual s

Rel ay St gr oup gr oup

t eachi ng af f l eader smember s

Pr ompt det ect i on

Emer gency measur es

Rel ay OJT St af f gr oup l eader sgr oup member s

Pr edi ct i on St andar dand i zat i on pr even and - t i on pl anni ng

Cor r ect handi ng of abnor mal i t i es

I mpr oved pr ocess st abi l i t y and saf et y

Pr epar i ng f or gener al pr ocess i nspect i on Est abl i sh a cur r i cul um uni t f or each equi pment cat egor y. Pr epar e gener al i nspect i on checkl i st s. Pr epar e t eachi ng mat er i al s f or gener al pr ocess i nspect i on t r ai ni ng. •

Pr ocess oper at i on and mani pul at i on manual s

•

Pr ocess adj ust ment and set t i ng manual s

•

Mat er i al and heat bal ances

•

Basi c chemi cal engi neer i ng l esson sheet s

•

Tr oubl eshoot i ng sheet s

•

Per i odi c over haul i nspect i on manual s

Sampl e gener al i nspect i on checkl i st f or mat s St ep 5- 1: Per f or mance and Funct i ons Checkl i st I t em #

Pr ocess composi t i on ( equi pment )

Per f or mance Funct i on Rol e

Specs.

Rel at i on to qual i t y

Why necessar y? Any l osses?

I mpr ovement pr oposal s ( si mpl i f i cat i on) ( capaci t y i ncr ease)

St ep 5- 2: Adj ust ment and Set t i ng Checkl i st Task I t em #

I t em #

I t em #

Adj ust ment / set poi nt

Why?

What ?

How?

Change i n pr oper t i e s

Cor r ect r ange/ Reasons

Ef f ect on qual i t y

St ep 5- 3: Checkl i st Pr ocess Pr obl ems and Human Er r or Anal ysi s

Past occur r ences Exampl e/ l ocat i on

Dat e/ Fr equency

Pr obl em descr i pt i on

( why di d i t happen?)

Act i on i n event of abnor mal i t y

Recur r ence pr event i on pr oposal

St ep 5- 4: Checkl i st f or Ant i ci pat i ng Ser i ous Acci dent Ant i ci pat ed War nis ng

Li kel y equi pment / par t

acci dent / di sast er

si gns/ phenomen a

Pr oj ect ed l oss/ damage

Cor r ect act i on

Gener al pr ocess i nspect i on t r ai ni ng

I mpl ement gener al pr ocess i nspect i on t r ai ni ng. Consol i dat e gener al i nspect i on t r ai ni ng.

•

Assess ski l l s.

•

Set act i on cr i t er i a.

•

Pr epar e mai nt enance pl ans.

•

Const r uct a r ecur r ence- pr event i on syst em.

St r eami ng aut onomous mai nt enance st andar ds Pat r ol Checki ng St andar ds For mul at e checki ng st andar ds and di spl ay on boar ds i n t he wor kpl ace • Pl an and si gnpost t he pat r ol r out e • I mpr ove vi sual cont r ol s and ext end t o al l equi pment and measur i ng i nst r ument s •

Pr ovi si onal Dai l y Cl eani ng, Checki ng and l ubr i cat i ng St andar ds Tr ansf er pr essur e gauges, ammet er s, over heat i ng, abnor mal noi se, vi br at i on, et c. t o newl y f or mul at ed pat r ol checki ng st andar ds

•

Per i odi c Checki ng and Lubr i cat i ng St andar ds Tr ansf er V- bel t s, chai ns, coupl i ngs, and ot her i t ems i nspect ed and ser vi ced ever y f ew mont hs t o newl y f or mul at ed per i odi c checki ng st andar ds

•

Tr ansf er i t ems wi t h a l ubr i cat i on i nt er val of 3 mont hs or mor e t o newl y f or mul at ed per i odi c l ubr i cat i ng st andar ds

•

Tr ansf er cl eani ng f r om t hese st andar ds and t o newl y f or mul at ed annual cl eani ng cal endar

For mul at e checki ng st andar ds f or each cat egor y i n t he 4- st ep t r ai ni ng pr ogr am • For mul at e l ubr i cat i ng st andar ds based on t he 4- st ep t r ai ni ng pr ogr am • I mpr ove ef f i ci ency – r ef i ne i mpr ovement of i naccessi bl e pl aces •

Annual Cl eani ng Cal endar

•

Pr epar e cal endar based on pr ovi si onal cl eani ng st andar ds • Ext end cl eani ng i nt er val s – r ef i ne i mpr ovement of cont ami nat i on sour ces •

When a br eakdown has t aken pl ace, when a def eat gas been pr oduced Fr om " Cont r ol by Resul t s" t o " Cont r ol by Causes"

Breakdown!

Abnorm al noise?

How t o deal wi t h br eakdowns or def ect s t hat have act ual l y t ake n pl ace? Breakdown! To use the experience ofthe breakdown as a lesson to im prove the ability to detect abnorm ality.

Ishould learn !

It's difficult to keep the standards.

"Standards m ust be easy to keep." Standards m ust constantly be checked and revised to im prove.

I f t he st andar ds have not been r evi sed f or mor e t han hal f a year , t hey ar e dead and usel ess

Under st andi ng of i r r egul ar i t y f or i nt er na l det er i or at i on by t he f i ve sense I f as s umpt i ons about di f f i c ul t or s c at t er i av oi d, t he onl y way i s y mpt oms . • Wer e t her e any i r r egul f ai l ur e oc c ur r ed?

t he l i f e s pan ar e ng i s i mpos s i bl e t o s t o under s t and t he ar s y mpt oms bef or e t he

•

Does t he f ai l ur e hav e s y mpt oms or not ?

•

What k i nd of s y mpt oms i ndi c at e t he f ai l ur e?

•

•

•

Why c an’ t t he f ai l ur e be under s t ood i n adv anc e f r om t he s y mpt oms ? What mus t be done t o under s t and t he s y mpt oms of t he f ai l ur e? I n or der f or oper at or s t o under s t and t he s y mpt oms of t he f ai l ur e, what k i nd of k nowl edge or s k i l l i s nec es s ar y ?

How t o det ect i nt er nal det er i or at i on Check during Operation

It is unusual.

Check by Operators' five senses

A little feverish.

M easuring by M easurem ent Tools

Exampl es of det ect i ng i nt er nal det er i or at i on * By finding out the changes in the cycle tim e ofthe equipm ent.

Breakage ofthe piston packing was revealed.

* By detecting the abnorm alnoise ofthe gear box,

The inspection ofthe inside revealed the wear ofthe gear and bearing.

Step 5: Autonomous Inspection Valutazione Costi / Benefici Step 5 1600

1300 1334,97

1400 1200 1000

Costi

800

Benefici

600 400

240 241,74

200 0 1

- Costs Inspection and cleaning activities Training - Losses in productivity

Benefits Further reduction of losses (maintenance activities) and consequent increase of OEE Reduction of inspection time through ECRS method Reduction of inspection activities made by professional maintenance team

346

Step 5: Autonomous Inspection – ECRS Method

ELIMINATE Double or obsolete controls not because of breakdowns.

COMBINE REDUCE

Controls of different type only on a component. Logistics combining controls on the same components, reducing the frequency of the controls on MTBF base.

SEMPLIFY Methods

of control, improving and developing devices of control visibility

347

Step 5: Autonomous Inspection – ECRS Method Example of reduction of inspection time after tool modification BEFORE

AFTER

Axial hole for oil lubrication flow

Inspection cycle frequency reduction

348

Step 5: results Costs/Benefits for Step

Cleaning and Inspection Time 800

740

700 2752 2279

2221 1686

1684

2022 1419

1161

€

2000

Costi Benefici

583

201

Step 2

Step 3

Step 4

600 600 500

419

Attività a macchina ferma Totale attività

400 300

280

192,81

200

117,88

100

0 Step 1

Minuti/settimana

4000

Step 5

36

0

59,19

25 15,00Obj=30 min/sett

1° STEP 2° STEP 3° STEP 4° STEP 5° STEP STEP

% Scraps 2,00 1,80 1,60 1,40 1,20 1,00 0,80 0,60 0,40 0,20 0,00

AM Tags 400 350 286

300

0,42

0,38

307

Step 4

Step 5

238

250

0,40

302

200

0,26

0,18

150

143

100

Step 1

Step 2

Step 3

Step 4

Step 5

Step 1

Step 2 Step 3

349

St ep 6

St ep 6: Syst emat i ze Aut onomous Mai nt enance

St ep 6: Syst emat i ze aut onomous mai nt enance

Activities •

•

•

Achi eve qual i t y mai nt enance and saf et y by est abl i shi ng cl ear pr ocedur es and st andar ds f or dependabl e aut onomous mai nt enance I mpr ove set up pr ocedur es and r educe wor k- i n- pr ocess Est abl i sh a syst em of sel f - management f or wor k pl ace f l ow, spar es, t ool s, wor k- i n- pr ocess, f i nal pr oduct s, dat a, et c.

St ep 6: Syst emat i ze aut onomous mai nt enance

Hardware Goals (Keys for workplace audits) •

•

•

Pi npoi nt r el at i onshi ps bet ween equi pment and qual i t y and est abl i sh a qual i t y mai nt enance syst em Revi ew and i mpr ove pl ant and equi pment l ayout s St andar di ze mai nt enance and cont r ol of t r anspor t equi pment , spar e par t s, t ool s, wor k- i n- cess, f i nal pr oduct s, dat a, passageways, cl eani ng equi pment , and so on, and i nt r oduce vi sual cont r ol s f or ever yt hi ng i n t he wor kpl ace

St ep 6: Syst emat i ze aut onomous mai nt enance

Human Goals (Keys for SGA audits) •

•

•

•

Expand t he spher e of sel f - management by syst emat i zi ng and st andar di zi ng cont r ol i t ems Hel p peopl e under st and t he r el at i onshi p bet ween equi pment and qual i t y and appr eci at e t he i mpor t ance of qual i t y mai nt enance By st andar di and col l ect i under st and t ai med at r ai

zi ng wor kpl ace management ng dat a, hel p peopl e he need f or i mpr ovement s si ng st andar ds

Have manager s and super vi sor s l ear n

Roles Managers (fostering St ep 6:ofSyst emat i zeand autStaff onomous mai nt enance

motivation, ability, and opportunity) •

•

•

•

Pr epar e syst em- f l ow di agr ams f or pr ocesses and gi ve i nst r uct i on i n st andar di zat i on Pr epar e qual i t y mai nt enance manual s t hat syst emat i ze t he r el at i onshi p bet ween equi pment and qual i t y, and use t hese f or i nst r uct i on Pr ovi di ng t echni cal suppor t f or t asks such as st andar di zi ng t he f l ow of wor k, and gi ve assi st ance i n per f ect i ng vi sual cont r ol s Gi ve educat i on and gui dance i n anal ysi s and i mpr ovement t echni ques

TABLE Driving Step 6 into Substeps Subst ep act i vi t y 1.

Maj or

Remedi es f ocused on qual i t y r esul Delt isneat i on of qual i t y as s ur anc e 1.

2. 3.

4. 5.

f l ow di agr am Pr oc es s qual i t y as s es s ment Pr ev ent i v e meas ur es agai ns t def ec t i v e pr oduc t out f l ow Pr oduc t handl i ng Can qual i t y def ec t s be det ec t ed when t hey oc c ur ?

TABLE Driving Step 6 into Substeps (Cont’d) Subst ep act i vi t y

Maj or

2. Remedi es f ocused on qual i t y causes 1. 2. 3. 4. 5.

Raw mat er i al c ont r ol Meas ur i ng appar at us c ont r ol J i g and di e c ont r ol Mac hi ni ng c ondi t i on c ont r ol Mi s t ak e- pr oof c ont r ol

3. Est abl i shment of pr ocess qual i t y assur ance syst em

Or gani z at i on and t i di ness

Cleaning is inspection

St ep 7

St ep 7: Pr act i ce Ful l Sel f - management

St ep 7: Pr act i ce f ul l sel f - management

Activities •

•

Evol ve act i vi t i es and st andar di ze i mpr ovement s i n l i ne wi t h company and pl ant pol i ci es and obj ect i ves, and r educe cost s by el i mi nat i ng wor k pl ace wast e I mpr ove equi pment f ur t her by keepi ng accur at e mai nt enance r ecor ds ( e. g. , MTBF) and anal yzi ng t he dat a i n t hem

St ep 7: Pr act i ce f ul l sel f - management

Hardware Goals (Keys for workplace audits) •

•

Anal yze i mpr ove r el i abi l qual i t y,

dat a i n var i ous ways t o equi pment and r ai se pr ocess i t y, saf et y, mai nt ai nabi l i t y, and oper abi l i t y

Pr i or i t i ze equi pment i mpr ovement s and ext end equi pment l i f et i mes and checki ng i nt er val s by usi ng har d dat a t o spot weakness

St ep 7: Pr act i ce f ul l sel f - management

Human Goals (Keys for SGA audits) •

•

•

I ncr ease awar eness of management by obj ect i ves and make ever yone t hor oughl y cost - consci ous ( i ncl udi ng mai nt enance cost s) Enabl e oper at or s t o per f or m si mpl e r epai r s and equi pment r est or at i on by t r ai ni ng t hem i n r epai r ski l l s I ncr ease oper at or s ’ abi l i t y t o r ecor d and anal yze dat a, and have t hem mast er i mpr ovement t echni ques

St ep 7: Pr act i ce f ul l sel f - management

Roles of Managers and Staff (fostering motivation, ability, and opportunity) •

• •

•

Expl ai n t he i mpor t ance of management by obj ect i ves Gi ve hands- on r epai r ski l l s t r ai ni ng Pr ovi de t echni cal backup f or equi pment i mpr ovement s, and r ai se oper at or s ’ i mpr ovement ski l l s by i ncl udi ng t hem i n i mpr ovement pr oj ect s Gi ve gui dance on st andar di zi ng i mpr ovement s and par t i ci pat i ng i n MP

Step 7 : Practice full self-management

The pr oduct i on mai nt enance and t he 10 mi nut es checki n g met hod

Ful l aut onomous mai nt enance 7 St eps f or Devel opi ng Aut onomous Mai nt enance

7

4

2 1

4 St eps t o Became a Capabl e Oper at or Pr act i ce f ul l sel f manage ment

Syst emat i 6 c aut onomou s Per f or m 5 genermaial nt enan ce pr ocess i nspect i on al Conduct gener

equi pment i nspect i on 3 Est abl i sh cl eani ng and checki ng st andar ds Addr ess cont ami nat i on sour c es and i nacc ess i bl e pl ac es Per f or m i ni t i al cl eani ng

Recogni z es si gns of abnor mal i t y ; deal s wi t h abnor mal i t i es cor r ect l y; per f or ms 4 per i odi c ov er haul check i ng and par t s r epl acement cor r ect l y Det ec t s abnor mal i t i es pr ompt l y ; t akes emer genc y act i on agai ns t abnor mal i t i es Under st ands pr oper t i es of mat er i al s bei ng handl ed; per f or ms cor r ect adj ust ment and s et t i ng

3

2

Under st ands pr ocess per f or mance and f unc t i ons; oper at es pr ocess cor r ect l y

1

5.

Audit Criteria and the Check List of Autonomous Maintenance

Aut onomous Mai nt enance Audi t s

Devel opi ng an aut onomous mai nt enance pr ogr am i n st eps, has t wo advant ages t hat make t he pr ogr am especi al l y ef f ect i ve: * Act i vi t i es pr oduce concr et e r esul t s as t hey pr oceed * Resul t s ar e conf i r med as par t of t he pr ogr am The si ngl e most i mpor t ant f act or i n t he success of an aut onomous mai nt enance pr ogr am i s conduct i ng a car ef ul audi t on compl et i on of each st ep t o conf i r m t he r esul t s achi eved and poi nt t he di r ect i on f or f ur t her wor k. The audi t pr ovi des gui dance wher e needed and gi ves peopl e a sense of achi evement . Whi l e t he st ep- by- st ep appr oach makes t he pr ogr am easi er f or t eams t o under st and as t hey pr ogr ess t hr ough i t , t he audi t s ser ve as mi l est ones on t he j our ney and hel p t o consol i dat e t he gai ns made 367 at each

Aut onomous Mai nt enance Audi t Di agr am Sel f - Audi t Gr oup l eader s and member s

Top- Management Audi t Di vi si on manager , pr omot i on of f i ce di r ect or , pr omot i on of f i ce st af f

Sect i on Manager ’ s Audi t Sect i on manager ( st af f , super vi sor s)

At each st ep NO Audi t ?

Gr oup act i vi t y r epor t •

Audi t Appl i cat i on For m YES ( Audi t sheet ) ①

Audi t ? •

Audi t sheet ② NO

Pl ace st i cker on equi pment

Poi nt out pr obl ems Pr ovi de gui dance and suppor t

Deci de r eadi ness f or t opAudi t meet i ng Audi t Appl i cat i on management audi t For m ② YES Pr omot i on Of f i ce Coor di nat e • schedul e Deci de whet her gr oup has Audi t ? passed st ep • Poi nt out pr obl ems • Audi t sheet ③ Gi ve gui dance and Gi ve expl anat i on advi and ce NO gui dance Audi t meet i ng

I ssue “ pass” st i cker f or st ep

•

Pass

374

AM Criteria St ep 1. I ni t i al Cl eani ng I ni t i al cl eani ng Wast e, dust and di r t ar e r emoved f r om t he mai n equi pment . The i nsi des of cover s and t he t anks ar e al so cl eaned.

Level 1

(Outside point) 10%

Inside 30%

50%

Processing 70%

90%

Ser vi ci ng f or t he basi c condi t i ons Cl eani ng, l ubr i cat i on and f ast eni ng ar e t hor oughl y done.

Level 2

(Outside point) 10%

Inside 30%

50%

Processing 70%

90%

How t o det ect abnor mal i t i es Level 3

The st r uct ur e and f unct i on of t he equi pment i s t hor oughl y under st ood. Anomal y can be det ect ed cor r ect l y. Oper at or s have t hor ough t aggi ng ski l l s.

(Tag on the outside 10%

Tag in the inside 30%

50%

Tag on the processing point) 70%

90%

Step 1. Initial Cleaning Measur es agai nst abnor mal i t i es By t aki ng measur es agai nst abnor mal i t i es, r est or at i on and i mpr ovement abi l i t i es ar e cont i nuousl y r ai sed.

Lev el 4

(Tag on the outside 10%

Tag in the inside 30%

50%

Tag on the processing point) 70%

90%

Thor ough execut i on of i ni t i al cl eani ng I ni t i al cl eani ng i s t hor oughl y execut ed and mai nt ai ned.

Lev el 5

(Outside point) 10%

Inside 30%

50%

Processing 70%

90%

St ep 2. Count er measur es agai nst Di r t and Dust Sour ces / Di f f i cul t Revel Ar ateas t o Access i on of def ect i ve sour ces The st at e of i ni t i al cl eani ng i s mai nt ai ned and di r t and dust sour ces and di f f i cul t ar eas t o access ar e cl ear l y shown.

Lev el 1

( I ni t i al cl eani ng 50% 70% Det 10% ect i on of di30%f f i cul t ar eas t o access)

Sour ces 90%

Count er measur es agai nst scat t er i ng Lev el 2

El i mi nat e t he sour ces of scat t er i ng r educe t he amount of di r t and dust l ocal i zed cover s and duct s ar e pl aced t o pr event scat t er i ng.

( Reduce t he amount of di r t and dust 10% 30% 50% Local i zed cover s)

Cover s 70%

90%

Count er measur es agai nst di f f i cul t spot s t o car r y out i nspect i on Lev el 3

For t he spot s di f f i cul t t o car r y out i nspect i on, measur es ar e t aken such as r emovi ng LSs, r eveal i ng pr ocessi ng poi nt s or i nst al l i ng i nspect i on wi ndows.

(Investigation 10%

Improvement 30%

50%

Easy inspection) 70%

90%

St ep 2. Count er measur es agai nst Di r t and Dust Sour ces / Di f f i cul t Easy Ar cleas t o Access eani ng / i nspect i on Lev el 4

I mpr ovement s f or easy i nspect i on ar e made such as r emovi ng LSs, r eveal i ng pr ocessi ng poi nt s or i nst al l i ng i nspect i on wi ndows.

(Improvement 10%

Easy cleaning 30%

50%

Easy inspection) 70%

90%

I nspect i on dur i ng oper at i on / zer o scat t er i ng Lev el 5

Pr ocessi ng poi nt can be seen even dur i ng oper at i on. No scat t er i ng. Cover s can be r emoved by one- t ouch devi ce and cl eani ng and i nspect i on can be done easi l y.

( Si mpl e cov er 10%

30%

I nspect i on dur i ng oper at i on 50% t er i ng) 70% 90% No scat

St ep 3. Pr epar at i on of Tempor ar y St andar ds of Aut onomous Mai nt enance Knowl edge of t he f unct i onal st r uct ur e of t he machi ne Level 1

Based on t he condi t i on t hat cl eani ng and l ubr i cat i ng par t s, met hods, st andar ds and per i ods ar e t empor ar i l y det er mi ned and t hat st r uct ur e / f unct i on / pr i nci pl es of t he equi pment ar e under st ood, l ubr i cat i on and hydr aul i c syst em char t s ar e pr epar ed.

( Tempor ar y det er mi nat i on Pr epar at i on of l ubr i cat i on, 10%

30%

Funct i onal st r uct ur e

50%

70%

90%

hydr aul i c syst em char t s)

Make t empor ar y st andar ds Cl eani ng / l ubr i cat i on / i nspect i on st andar ds whi ch can be i mpl ement ed wi t hi n t he l i mi t ed amount of t i me ar e pr epar ed.

Level 2

( Make t empor ar y st andar ds 50% Det ect i on10% l oss due t 30% o i nspect i on)

I nspect i on 70%

90%

Revi ew t he t empor ar y st andar ds Level 3

By r epeat i ng t he i nspect i on based on t he t empor ar y st andar ds, some par t s of i nspect i on i t ems or per i ods needi ng amendment ar e r eveal ed.

( I nspect i on Reveal t he i t ems t o be amended, 10%

30%

50%

Make amendment )

I nt ensi ve i t ems 70%

90%

St ep 3. Pr epar at i on of Tempor ar y St andar ds of Aut onomous Mai nt enance Easy i nspect i on Lev el 4

Abnor mal i t i es can be f ound easi l y by usi ng vi sual cont r ol . Equi pment i s i mpr oved i n such a way as t o car r y out easy i nspect i on wi t hout bendi ng.

(Staring at 10%

Watch carefully 30%

50%

At a glance) 70%

90%

St andar di zed, ef f i ci ent and ef f ect i ve i nspect i on Lev el 5

I nspect i on i t ems and i nspect i on per i ods ar e put t oget her . Ef f i ci ent and ef f ect i ve i nspect i on i s car r i ed out wi t hi n 10 mi n. / day ( St andar di zed / ef f i ci ent / ef f ect i ve i nspect i on) .

(Within 30 min. 10%

Within 20 min. 30%

50%

Within 10 min.) 70%

90%

St ep 4. Over al l I nspect i on I nspect i on based on t he t empor ar y st andar ds Lev el 1

Based on cl eani ng / l ubr i cat i on / i nspect i on st andar ds, t empor ar y i nspect i on st andar ds ar e made f or each over al l i nspect i on i t ems ( 6 i t ems) and mi nor def ect i ves ar e r eveal ed.

( I nspect i on Revi ew / Det er mi nat i on of st andar ds 10%Revel at i on 30% 50% 70% 90% of def ect i ves) Ski l l t r ai ni ng by super vi sor s and t eam l eader s Super vi sor s and t eam l eader s make one- poi nt l essons f or each subj ect by whi ch t r ai ni ng i s car r i ed out t o oper at or s.

Lev el 2

( Make t r ai ni ng mat er i al s 10% 30% Hor i zont al expansi on)

Educat i on & t r ai ni ng 50%

70%

90%

Pr epar e st andar ds Thr ough r evi ewi ng t empor ar y st andar ds, st andar ds ar e pr epar ed and mi nut e def ec t i s r est or ed and i mpr ov ed.

Lev el 3

( Pr epar at i on of st andar ds 10% 30% I mpr ovem50% ent )

Rest or at i on 70%

90%

St ep 4. Over al l I nspect i on QA condi t i ons Lev el 4

Consi der i ng t he r el at i onshi p bet ween equi pment and qual i t y, t he opt i mal pr ocessi ng condi t i on i s det er mi ned ( Mai nt ai n t he cont r ol i t ems of manuf act ur i ng qual i t y and qual i t y st andar ds) .

( I nvest i gat i on anal ysi s 10% Mai nt30%enance)

Opt i mal pr ocessi ng condi t i on 50%

70%

90%

Smal l r epai r Smal l r epai r s can be car r i ed out not by mai nt enance per sonnel but by oper at i on hi msel f .

Lev el 5

(Supervisors 10%

Leaders 30%

50%

Operators) 70%

90%

St ep 5. Aut onomous i nspect i on Revi ew of t he st andar ds Lev el 1

Cl eani ng / l ubr i cat i on / i nspect i on st andar ds ar e r evi ewed i n or der t o pr event t he r ecur r ence of br eakdowns / def ect i ves / mi nor st oppages / mi s- i nspect i ons.

(Review 10% recurrence)

Amendment 30%

50%

Zero 70%

90%

Dai l y i nspect i on Lev el 2

St andar ds ar e r evi ewed. Oper at or s check t hei r equi pment by t hei r 5 senses. Ther ef or e, anomal y can be det ect ed at an ear l y st age.

( Check by 5 senses Count er measur es agai nst 10%

30%

Det ect abnor mal i t i es 50%

70%

abnor mal i t i es)

Spar e par t s management Lev el 3

90%

Exchange par t s / spar e par t s of t he equi pment ar e managed and t he concer ned peopl e have knowl edge and ski l l s on exchangi ng par t s and pr event i on of br eakdown.

(Management 10%

Skills 30%

50%

Prevention) 70%

90%

St ep 5. Aut onomous i nspect i on Si mpl e di agnosi s Lev el 4

Oper at or s can est i mat e t he per i od of det er i or at i on l i mi t of t he equi pment and can det er mi ne t he det er i or at i on l i mi t f or each mode.

(Estimate 10%

For each mode 30%

50%

Establish the limit) 70%

90%

Mai nt enance t r ai ni ng on pl anned mai nt enance Ther e i s a scheme by whi ch oper at or s ar e t r ai ned t o i mpr ove t hei r mai nt enance ski l l s.

Lev el 5

(Supervisors 10%

Leaders 30%

50%

Operators) 70%

90%

St ep 6. St andar di zat i on St andar di zat i on of j i gs and t ool s Nor mal r epet i t i ve oper at i ons ar e st andar di zed and j i gs and t ool s ar e st andar di zed f or usage i n 5S act i vi t i es.

Lev el 1

(5S

3 normal operations 10%

30%

50%

Standardization) 70%

90%

St andar di zat i on of oper at i ons Lev el 2

Mur i ( unnat ur al oper at i on) , Mur a ( i r r egul ar oper at i on) , Muda ( non val ue added oper at i on) ar e gr asped among movement s i n t he oper at i on, anal yzed, i mpr oved, and oper at i ons ar e st andar di zed.

(Analysis 10% Standardization)

Improvement 30%

50%

70%

90%

I mpr ovement ski l l s I mpr ovement act i vi t i es ar e pr act i ced at t he shop and i mpr ovement ski l l s ar e cont i nuousl y r ai sed.

Lev el 3

( Tr ai ni ng of

I mpr ovement I mpr ovement ski l l s

10%

i mpr ovement ski l l s

30%

50%

70%

ar e r ai sed)

90%

act i vi t i es

St ep 6. St andar di zat i on Saf et y cont r ol Zer o br eakdown, zer o def ect i ve, zer o mi nor st oppage and zer o acci dent ar e act ual i zed.

Lev el 4

(Zero accident 10%

Zero injury 30%

50%

Zero near-misses) 70%

90%

Shop management Ther e i s a scheme by whi ch r educt i on of l osses and mai nt enance cost r educt i on ar e cont i nuousl y i n pr ogr ess.

Lev el 5

( Gr as p l oss es 10%

Reduc e c ost 30% i nuous 50%ovem Cont i mpr ent )

70%

90%

St ep 7. Thor ough aut onomous management Act i vi t y boar d Lev el 1

Pol i ci es ar e managed by t he act i vi t y boar d and pol i ci es, r esul t s, pr obl ems and t hemes ar e cl ar i f i ed showi ng cont ent s of act i vi t i es.

(Notice board board) 10%

Activity board 30%

Utilization

50%

70%

90%

Gr oup meet i ng Lev el 2

The t r ends of br eakdown l osses, def ect i ve l osses and mi nor st oppage l osses ar e anal yz ed and t he i mpr ovement pl ans ar e di scussed at gr oup meet i ngs.

( Cl ar i f i cat i on of pr obl ems 10%

30%

Meet i ng 50% Im pr ov ement )

70%

90%

I ndi vi dual i mpr ovement Lev el 3

The r esul t s and pr obl ems of manuf act ur i ng gr oups ar e known and f ocused i mpr ovement ( PPA, I E met hods, out act i vel y.

( Cl ar i f i cat i on of pr obl ems 10% 30% r ence) Zer o r ecur

Count er measur es 50%

70%

90%

et c. ) i s car r i ed

St ep 7. Thor ough aut onomous management Common use of i nf or mat i on Level 4

Common use of i nf or mat i on i s car r i ed out at i mpr ovement case st udy meet i ngs and / or gr oup wor kshops. I mpr ovement abi l i t y at t he wor kshop i s i mpr oved.

( St udy meet i ngs 10% 30% Hor i zont al expansi on)50%

Common use of i nf or mat i on 70%

90%

Mai nt enance car r i ed out mai nl y by oper at or s Level 5

Oper at or s can t ake car e of mai nt enance act i vi t i es agai nst def ect i ves and br eakdowns, such as r est or i ng and i mpr ovement act i vi t i es. Speci al mai nt enance per sonnel ar e engaged i n devel opi ng mor e advanced mai nt enance .

( Smal l r epai r 10%

Mai nt enance t r ai ni ng 30%

50% Mai nt enance)

70%

90%

TABLE TABLE

Step 1 No. 1. 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10

Step 1: Initial Cleaning Autonomous Maintenance Audit Sheets

Sheet 1 of 5

Audit points

Results

Group activity (General) Are aims of Step 1 understood adequately? Is activity plan made in advance? Well executed? Are managers’ models well understood? Is activity board adequately utilized? Are defective areas accurately located? Confirmed by all members? Are previously overlooked defective areas detectable with current knowledge? Are identification tags collected and kept after remedies? Are questions sufficiently posed? Are questions definitely resolved? Understood by all members? Are sources of contamination accurately located? Written onto source of contamination list?

TABLE (-Continued) Step 1 1.11 1.12 1.13 1.14 1.15 1.16 1.17 1.18 1.19 1.20

Step 1: Initial Cleaning Autonomous Maintenance Audit Sheets

Is up/downtime work clearly distinguished? Are safety matters carefully respected? Are TPM activity hours and frequency adequate? Is more efficient way of TPM activity pursued? Are used spare parts and consumables recorded? Is meeting after on-site activity definitely held? Reports submitted? Is activity participated in by all members? Are all members cooperating equally? Not led by particular member? Are noteworthy ideas introduced actively to other PM groups? Is cooperation with full-time maintenance satisfactory?

Sheet 2 of 5

TABLE (-Continued) Step 1 2 2.1 (1) (2) (3) (4) (5) (6) (7) (8)

Step 1: Initial Cleaning Autonomous Maintenance Audit Sheets

Equipment (Main body and surroundings) No contamination or foreign materials at locations as listed below? Rotating, reciprocating or positioning parts Parts contacting workpieces Frames, beds or any other member Conveyors, chutes or any other material transfer facilities Tools, jigs or any other auxiliary devices Sensors, microswitches, instruments, lighting (exterior/interior) of consoles/panels Air filters, regulators, lubricators, cylinders, solenoid valves or other pneumatic devices Motors, belts or safety covers and surroundings

Sheet 3 of 5

TABLE Step 1 2.2 (1) (2) (3) (4) 2.3 2.4 2.5 2.6 2.7 2.8 2.9

(-Continued)

Step 1: Initial Cleaning

Autonomous Maintenance Audit Sheets No deteriorated or defective parts as listed below? Loose, damaged or missing nuts/bolts Looseness in sliding parts, fixtures of tools or jigs Abnormal noise in motors, solenoid valves, etc. Damaged pipes, hoses or cables Are tools and jigs stored at designated locations? No shortage or damage? No nuts, bolts, tools, workpieces or any other unnecessary materials in and around equipment? No dropped parts on floor? No unnecessary pieces of equipment? Can quality/defective products or scraps be clearly distinguished? Are labels and name plates clean and legible? Do status display and warning lamps function properly? Do safety devices function properly?

Sheet 4 of 5

TABLE (-Continued) Step 1 3. 3.1 3.2 3.3 3.4 4. 4.1 5. 5.1

Step 1: Initial Cleaning Autonomous Maintenance Audit Sheets

Lubrication No dirt, dust or leakage in and around air lubricators, oil reservoirs or centralized systems? Is oil level proper? Adequate lubricants at lubricating surfaces? No contamination at lubricating points and surfaces? Are lubricants not contaminated? Not deteriorated? Short remedial program Is outline of short remedial program known? Residual issues No residual questions, equipment defects? If so, do reasonable explanations exist? Are plans and schedules to solve these issues clear?

Sheet 5 of 5

TABLE Step 2 No. 1. 1.1 1.2 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9

Step 2: Countermeasures to Sources of Contamination Autonomous Maintenance Audit Sheets

Sheet 1 of 6

Audit points

Results

Step 1 conditions Is cleanliness attained in Step 1 well maintained? Are residual issues left over from Step 1 resolved? Group activity (General) Are aims of Step 2 understood adequately? Is activity plan made in advance? Well executed? Are managers’ models well understood? Is activity board adequately utilized? Are defective areas accurately located? Confirmed by all members? No overlooked defective areas detectable with current knowledge? Are identification tags collected and kept after remedies? Are questions sufficiently posed? Are questions definitely resolved? Understood by all members?

TABLE (-Continued) Step 2 2.10 (1) (2) (3) (4) 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18 2.19

Step 2: Countermeasures to Sources of Contamination

Autonomous Maintenance Audit Sheets Is activity developed in following priority? Remove generation of contaminants at source. Prevent contaminants from dispersing. Improve cleaning methods and tools. Modify equipment to make cleaning tasks easier. Are safety matters carefully respected? Are TPM activity hours and frequency adequate? Is more efficient way of TPM activity pursued? Are used spare parts and consumable recorded? Is meeting after on-site activity definitely held? Reports submitted? Is activity participated in by all members? Are all members cooperating equally? Not led by particular member? Are noteworthy ideas introduced actively to other PM groups? Is cooperation with full-time maintenance satisfactory?

Sheet 2 of 6

TABLE (-Continued) Step 2 3. 3.1 3.2 3.3 3.4 3.5 3.6

Step 2: Countermeasures to Sources of Contamination Autonomous Maintenance Audit Sheets

Tentative cleaning standards Are cleaning time targets, work allocation and areas clearly specified by manager? Are these prescriptions well understood? Are tentative cleaning standards set at the beginning of Step 2? Are cleaning intervals identified to maintain cleanliness achieved in Step 1? Are tentative cleaning standards revised as every remedial action is taken? Is cleaning work to be done during up/downtime of equipment clearly distinguished? Well understood? Can everyone clean equipment in accordance with cleaning standards? Time targets achieved? If not, are adequate plans and schedules prepared?

Sheet 3 of 6

Step 2: Countermeasures to Sources of Contamination TABLE (-Continued) Step 2 Autonomous Maintenance Audit Sheets Sheet 4 of 6 4. 4.1 4.2 4.3 4.4 4.5 5. 5.1 5.2 5.3

Sources of contamination Are remedial actions taken deliberately, based on detailed assessment of actual generating conditions of contaminants? Are locations and manners of contaminants clearly recognized by detailed observation? Where-where analysis conducted, if necessary? Are structure and function of equipment sufficiently learned? Why-why analysis conducted, if necessary? Are all simple sources resulting from deteriorated parts such as water, oil and stream leakage remedied? Are cost and effects of remedies reviewed? Actual figures recorded? Difficult cleaning area Are remedial actions taken deliberately, based on detailed assessment of actual conditions of cleaning tasks in awkward work areas? Are sources thoroughly remedied to make actions against difficult cleaning areas unnecessary? Are costs and effects of remedies reviewed? Actual figures recorded?

TABLE (-Continued) Step 2 6. 6.1 6.2 6.3 6.4 6.5 6.6 7. 7.1 7.2 7.3

Step 2: Countermeasures to Sources of Contamination Autonomous Maintenance Audit Sheets

Equipment (Main body and surroundings) Are tools and jigs stored at designated locations? No shortage or damage? No unnecessary pieces of equipment? No unnecessary materials in process? No dropped parts on floor? Can quality/defective products or scraps be clearly distinguished? Do status display and warning lamps function properly? Do safety devices function properly? Lubrication No dirt, dust or leakage in and around air lubricators, oil reservoirs or centralized systems? Is oil level proper? Adequate lubricants at lubricating surfaces? Are lubricants not contaminated? Not deteriorated?

Sheet 5 of 6

TABLE (-Continued) Step 2 8. 8.1 8.2 9. 9.1 9.2 9.3 9.4 9.5 10. 10.1 10.2

Step 2: Countermeasures to Sources of Contamination Autonomous Maintenance Audit Sheets

Visual control Are visual controls devised to facilitate cleaning tasks? Are available visual controls installed using current technical knowledge and skill? Short remedial program Is subject selected from the six big losses? Are problems clearly identified? Targets pinpointed? No easy countermeasures taken? Are cost and effects of program reviewed? Actual figures recorded? Are preventive measures against recurrence of problems provided? Residual issues No residual questions, equipment defects? Are secure plans and schedules for corrective actions prepared? No residual remedies against sources of contamination and difficult cleaning areas? If so, do reasonable explanations exist? Are plans and schedules to solve these issues clear?

Sheet 6 of 6

TABLE Step 3 No. 1. 1.1 1.2 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8

Step 3: Cleaning and Lubricating Standards Autonomous Maintenance Audit Sheets

Sheet 1 of 7

Audit points

Results

Step 2 conditions Is cleanliness attained in Step 2 well maintained? Cleaning standards definitely observed? Are residual issues left over from Step 2 resolved? Group activity (General) Are aims of Step 3 understood adequately? Is activity plan made in advance? Well executed? Are managers’ models well understood? Is TPM activity board adequately utilized? Are safety matters carefully respected? Are TPM activity hours and frequency adequate? Is more efficient way of TPM activity pursued? Are used spare parts and consumables recorded?

TABLE (-Continued) Step 3 No. 2.9 2.10 2.11 2.12 2.13 3. 3.1 3.2 3.3

Step 3: Cleaning and Lubricating Standards Autonomous Maintenance Audit Sheets

Sheet 2 of 7

Audit points

Results

Is meeting after on-site activity definitely held? Reports submitted? Is activity participated in by all members? No indication of dropout? Are all members cooperating equally? Not led by particular member? Are noteworthy ideas introduced actively to other PM groups? Is cooperation with full-time maintenance satisfactory? Education (Lubrication) Is education for group leaders and operators conducted? More than 80% of subject matter comprehended? Are lubrication-related devices, parts type, name, structure and function understood? Are phenomena, causes, criteria, evaluation and remedies of lubrication-related equipment defects recognized? Can everyone actually inspect equipment?

TABLE Step 3 No. 3.4 (1) (2) (3) (4) 4. 4.1 4.2 4.3 4.4 4.5 4.6

(-Continued)

Step 3: Cleaning and Lubricating Standards

Autonomous Maintenance Audit Sheets

Sheet 3 of 7

Audit points

Results

Does everyone know matters in terms of equipment for which they are responsible as listed here: Lubricating points and surfaces. Type of lubricants to be applied. Inspection and lubrication intervals. Check points. Overall inspection (Lubrication) Are all lubricating points and surfaces definitely located? Adequate lubricants at lubricating surfaces? No wear, overheating, abnormal noise or odor at lubricating surfaces? No contaminated, leaked, damaged or clogged grease cups, nipples or any other lubricating points? No pipes, valves and fittings in remote or centralized systems kept in above conditions? Are lubricants not contaminated? Not deteriorated?

TABLE (-Continued) Step 3 No. 5. 5.1 5.2 5.3 5.4 5.5

Step 3: Cleaning and Lubricating Standards Autonomous Maintenance Audit Sheets

Sheet 4 of 7

Audit points

Results

Tentative lubricating standards Are lubricating time targets, work allocation and areas clearly specified by manager? Are these prescriptions well understood? Are tentative lubricating standards set immediately after overall inspection? Are tentative lubricating standards revised after every remedial action? Is lubricating work to be done during up/downtime of equipment clearly distinguished? Well understood? Can everyone inspect and lubricate equipment in accordance with tentative lubrication standards? Time targets achieved? If not, are adequate plans and schedules prepared?

TABLE (-Continued) Step 3 No. 6. 6.1 6.2 6.3 7. 7.1 7.2 7.3

Step 3: Cleaning and Lubricating Standards Autonomous Maintenance Audit Sheets

Sheet 5 of 7

Audit points

Results

Cleaning/lubricating standards Are cleaning/lubricating standards comprised of systematic combinations of tentative cleaning standards set in Step 2 and lubricating standards set in Step 3? Can everyone locate any defects relating to basic equipment conditions? Can everyone clean and lubricate in accordance with standards? Time target achieved? If not, are adequate plans and schedules prepared? Equipment (Main body and surroundings) Are tools and jigs stored at designated locations? No shortage or damage? No unnecessary pieces or equipment? No unnecessary materials in process? No dropped parts on floor?

TABLE (-Continued) Step 3 No. 7.4 7.5 7.6 8 8.1 8.2 9. 9.1 9.2

Step 3: Cleaning and Lubricating Standards Autonomous Maintenance Audit Sheets

Sheet 6 of 7

Audit points

Results

Can quality, defective products or scraps be clearly distinguished? Do status display and warning lamps function properly? Do safety devices function properly? Visual control Are color lubrication control and visual controls such as lubrication labels, instructions for oil levels or adequate ranges of instruments thoroughly applied? Are new visual controls devised? Noteworthy ideas actively revealed to other PM groups? Short remedial program Is subject selected from the six big loses? Are problems clearly identified? Targets pinpointed?

TABLE (-Continued) Step 3 No. 9.3 9.4 9.5 10. 10.1 10.2

Step 3: Cleaning and Lubricating Standards Autonomous Maintenance Audit Sheets

Sheet 7 of 7

Audit points

Results

No easy countermeasures taken? Are cost and effects of program reviewed? Actual figures recorded? Are preventive measures against recurrence of problems provided? Residual issues No residual questions, equipment defects? Are secure plans and schedules for corrective actions prepared? No residual remedies against difficult lubricating areas? If so, do reasonable explanations exist? Are plans and schedules to solve these issues clear?

TABLE Step 4 No. 1. 1.1 1.2 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8

Step 4: Overall Inspection Autonomous Maintenance Audit Sheets

Sheet 1 of 10

Audit points

Results

Step 3 conditions Are the basic equipment conditions attained in Step 3 well maintained? Cleaning/lubricating standards definitely observed? Are residual issues left over from Step 2 or previous sub step resolved? Group activity (General) Are aims of Step 4 understood adequately? Is activity plan made in advance? Well executed? Are managers’ models well understood? Is activity board adequately utilized? Are safety matters carefully respected? Are TPM activity hours and frequency adequate? Is more efficient way of TPM activity pursued? Are used spare parts and consumables recorded?

TABLE (-Continued) Step 4 No. 2.9 2.10 2.11 2.12 2.13 3. 3.1 3.2 3.3

Step 4: Overall Inspection Autonomous Maintenance Audit Sheets

Sheet 2 of 10

Audit points

Results

Is meeting after on-site activity definitely held? Reports submitted? Is activity participated in by all members? No indication of dropout? Are all members cooperating equally? Not led by particular member? Are noteworthy ideas introduced actively to other PM groups? Is cooperation with full-time maintenance satisfactory? Inspection education (By each category) Is education for group leaders and operators conducted? More than 80% of subject matter comprehended? Are parts type, name, structure and function of equipment understood? Are phenomena, causes, criteria, evaluation and remedies of equipment defects understood? Can everyone actually inspect equipment?

TABLE (-Continued) Step 4 No. 3.4 4. 5. 5.1 5.2 5.3 5.4 5.5

Step 4: Overall Inspection

Autonomous Maintenance Audit Sheets

Sheet 3 of 10

Audit points

Results

Does everyone know relevant inspecting items and check points in equipment for which they are responsible? Overall inspection (By each category) 　 Use attached sheets for each inspection category. Tentative inspecting standards (By each category) Are inspecting time targets, 　 work allocation and areas clearly specified by manager? Are these prescriptions well understood? Are tentative inspecting standards set immediately after overall inspection? Are inspecting standards revised after every remedial action? Is inspecting to be done during up/downtime of equipment clearly distinguished? Well understood? Can everyone conduct routine inspection in accordance with tentative inspecting standards? Can defective parts actually be discovered?

TABLE (-Continued) Step 4 No. 5.6 5.7 6. 6.1 6.2 6.3 6.4 6.5 6.6

Step 4: Overall Inspection Autonomous Maintenance Audit Sheets

Sheet 4 of 10

Audit points

Results

Are inspecting intervals estimated? Are time targets achieved? If not, are adequate plans and schedules prepared? Equipment (Main body and surroundings) Are tools and jigs stored at designated locations? No shortage or damage? No unnecessary pieces or equipment? No unnecessary materials in process? No dropped parts on floor? Can quality/defective products or scraps be clearly distinguished? Do status display and warning lamps function properly? Do safety devices function properly?

TABLE (-Continued) Step 4 No. 7. 7.1 7.2 8. 8.1 8.2 8.3 8.4 8.5

Step 4: Overall Inspection Autonomous Maintenance Audit Sheets

Sheet 5 of 10

Audit points

Results

Visual control Are visual controls thoroughly applied to facilitate inspecting tasks? Are new visual controls devised? Noteworthy ideas actively revealed to other PM groups? Short remedial program Is subject selected from the six big loses? Are problems clearly identified? Targets pinpointed? No easy countermeasures taken? Are cost and effects of program reviewed? Actual figures recorded? Are preventive measures against recurrence of problems provided?

TABLE (-Continued) Step 4 No. 9. 9.1 9.2

Step 4: Overall Inspection Autonomous Maintenance Audit Sheets

Sheet 6 of 10

Audit points

Results

Residual issues No residual questions, equipment defects? Are secure plans and schedules for corrective actions prepared? No residual remedies against difficult inspecting areas? If so, do reasonable explanations exist? Are plans and schedules to solve these issues clear?

TABLE (-Continued)

Step 4 No. 4. 4.1 4.2 4.3 4.4 4.5 4.6

Step 4: Overall Inspection

Autonomous Maintenance Audit Sheets

Sheet 7 of 10

Audit points

Results

Step 4-1 (Overall fastener inspection) No corroded, loose or bent nuts and bolts? Minimum two threads exposed? No damaged threads? Are lengths of bolts adequate? Are looseness prevention methods such as washers properly used? Are double nuts or match marks used for critical bolts? Are other fastener-related parts inspected? Are all discovered defective parts corrected?

TABLE (-Continued) Step 4 No. 4. 4.1 4.2 4.3

4.4 4.5

Step 4: Overall Inspection Autonomous Maintenance Audit Sheets

Sheet 8 of 10

Audit points

Results

Step 4-2 (Overall electrical inspection) No contamination, scratched, bent or loose connections at cables and conduit pipes? None touching water, steam or moving items? No threat to safety? No disconnections or breakages in ground wires? Do instruments installed on consoles, control panels or distribution boards function properly? No burned out lamps? Are switches easy to use? No possibility of operation mistakes? Are visual controls properly applied? No dirt, dust or any other contamination in/outside consoles, control panels and distribution boards? Are wirings neat? No unnecessary materials left in boxes? Sufficient ventilation? Do motors produce no abnormal heat, noise or order? No loose setting bolts? Is lubrication satisfactory?

TABLE (-Continued) Step 4 No. 4.6 4.7 4.8 4. 4.1 4.2 4.3 4.4 4.5 4.6 4.7

Step 4: Overall Inspection Autonomous Maintenance Audit Sheets

Sheet 9 of 10

Audit points

Results

No contaminated or damaged limit, proximity switches or any other sensors? No improper actuations? Are all electrical and instrumental parts, devices, wiring, or conduit pipes inspected? Are all discovered defective parts corrected? Step 4-3 (Overall power transmission inspection) No deteriorated or oil contaminated belts? Are belt tensions proper? No worn or misaligned pulleys? No wear or slack in chains or sprockets? No oily contamination around chains? No damage, misalignment, loose fixtures or play in shaft? No overheating, vibration or noise at bearings? No noise, vibration or overheating at gears, breaks? Are critical areas visible through safety cover? Are covers adequately modified? Are all power transmission parts and devices inspected? Are all discovered defective parts corrected?

TABLE (-Continued) Step 4 No. 4. 4.1 4.2 4.3 4.4 4.5 4.6 4.7

Step 4: Overall Inspection Autonomous Maintenance Audit Sheets

Sheet 10 of 10

Audit points

Results

Step 4-4 (Overall hydraulic/pneumatic inspection) No contamination, damage, leakage or vibration in hydraulic and pneumatic equipment, pipes, hoses, valves, fittings or any other parts? No abnormal noise, vibration or overheating in rotary machinery, motors, solenoid and selector vales, or any other hydraulic and pneumatic parts? Are air filters, regulators and lubricators properly installed? Easy to inspect for oil quantity? Oil levels satisfactory? No foreign particle in filters? Condensed water drained? Are pressure gauges, thermometers, level gauges properly installed? Easy to inspect? Actuating normally? Are tubes, pipes and hoses properly installed? Are all other hydraulic/pneumatic parts and devices inspected? Are all discovered defective parts corrected?

TABLE Step 5 No. 1. 1.1 1.2 1.3 1.4 1.5 2. 2.1 2.2 2.3 2.4 2.5

Step 5: Autonomous Maintenance standards Autonomous Maintenance Audit Sheets

Sheet 1 of 6

Audit points

Results

Step 1 through 4 review Are equipment detected from Step 1 through 4 definitely corrected? Are remedial actions to sources of contamination completed? Are difficult areas for conducting routine maintenance adequately modified? No residual issues in above? If so, do reasonable explanations exist? Are plans and schedules to solve these issues clear? No unanswered questions? Group activity (General) Are aims of Step 5 understood adequately? Is activity plan made in advance? Well executed? Are managers’ models well understood? Is activity board adequately utilized? Are safety matters carefully respected?

TABLE (-Continued) Step 5 No. 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 3. 3.1

Step 5: Autonomous Maintenance standards Autonomous Maintenance Audit Sheets

Sheet 2 of 6

Audit points

Results

Are TPM activity hours and frequency adequate? Is more efficient way of TPM activity pursued? Are used spare parts and consumables recorded? Is meeting after on-site activity definitely held? Reports submitted? Is activity participated in by all members? No indication of dropout? Are all members cooperating equally? Not led by particular member? Are noteworthy ideas introduced actively to other PM groups? Is cooperation with full-time maintenance satisfactory? Routine maintenance activity Are cleaning, lubricating and inspecting times sufficiently reduced? Are relevant standards faithfully revised whenever work methods or equipment are modified?

TABLE (-Continued) Step 5 No. 3.2 3.3 3.4 3.5 3.6

Step 5: Autonomous Maintenance standards Autonomous Maintenance Audit Sheets

Sheet 3 of 6

Audit points

Results

Are breakdowns caused by internal deterioration prevented with the five senses? Is warning card system effectively operated? Are countermeasures against misoperation taken in cooperation with full-time maintenance? Are remarkable causes of breakdowns and misoperation prevention actively taught to all PM groups? Are related standards always reviewed? Are standards prepared in the past steps sufficiently assessed in terms of safety, quality and breakdowns? Are discovered problems remedied? Are tentative inspecting standards set in Step 4 thoroughly reviewed by making a detailed comparison with those prepared by full-time maintenance? Is allocation of inspecting tasks between autonomous and full-time maintenance adequate?

TABLE (-Continued) Step 5 No. 3.7 3.8 3.9 3.10

4. 4.1 4.2 4.3

Step 5: Autonomous Maintenance standards Autonomous Maintenance Audit Sheets

Sheet 4 of 6

Audit points

Results

Are autonomous maintenance standards, by systematically combining various standards, set in the past steps? Are maintenance schedules prepared to definitely conduct operator’s routine maintenance? Faithfully executed? Is routine maintenance work to be done during up/downtime of equipment clearly distinguished? Well understood? Can everyone clean, lubricate and inspect equipment in accordance with autonomous maintenance standards? Time targets achieved? If not, are adequate plans and schedules prepared? Equipment (Main body and surroundings) Are tools and jigs stored at designated locations? No shortage or damage? No unnecessary pieces of equipment? No unnecessary materials in process? No dropped parts on floor?

TABLE (-Continued) Step 5 No. 4.4 4.5 4.6 5. 5.1 5.2 6. 6.1 6.2 6.3 6.4 6.5

Step 5: Autonomous Maintenance standards Autonomous Maintenance Audit Sheets

Sheet 5 of 6

Audit points

Results

Can quality/defective products or scraps be clearly distinguished? Do status display and warning lamps function properly? Do safety devices function properly? Visual control Are visual controls thoroughly applied to facilitate inspecting tasks? Are new visual controls devised? Noteworthy ideas actively revealed to other PM groups? Short remedial program Is subject selected from the six big losses? Are matters of quality being dealt with? Are problems clearly identified? Targets pinpointed? No easy countermeasures taken? Are cost and effects of program reviewed? Actual figures recorded?

TABLE (-Continued)

Step 5 No. 6.6 7. 7.1

Step 5: Autonomous Maintenance standards

Autonomous Maintenance Audit Sheets

Sheet 6 of 6

Audit points

Results

Are preventive measures against recurrence of problems provided? Residual issues No residual equipment related issues? If so, do reasonable explanations exist? Are plans and schedules to solve these issues clear? Is adequate assistance of full-time maintenance arranged?

TABLE TABLE

Step 6 No. 1. 1.1 1.2 1.3

2. 2.1 2.2 2.3 2.4 2.5

Step 6: Process Quality Assurance Autonomous Maintenance Audit Sheets

Sheet 1 of 8

Audit points

Results

Step 5 condition Are all equipment-related problems solved? No residual issues? Is operators’ routine maintenance definitely executed in accordance with autonomous maintenance standards and schedules? Are cause analysis and preventive measures taken in each event of breakdowns or minor stoppages occurring in spite of secure observation of autonomous maintenance standards? Assistance of full-time maintenance satisfactory? Group activity (General) Are aims of Step 6 understood adequately? Is activity plan made in advance? Well executed? Are managers’ models well understood? Is activity board adequately utilized? Are safety matters carefully respected?

TABLE (-Continued) Step 6 No. 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 3. 4. 4.1

Step 6: Process Quality Assurance Autonomous Maintenance Audit Sheets

Sheet 2 of 8

Audit points

Results

Are TPM activity hours and frequency adequate? Is more efficient way of TPM activity pursued? Are used spare parts and consumables recorded? Is meeting after on-site activity definitely held? Reports submitted? Is activity participated in by all members? No indication of dropout? Are all members cooperating equally? Not led by particular member? Are noteworthy ideas introduced actively to other PM groups? Is cooperation with full-time maintenance satisfactory? Sub step activities 　 Use attached sheets. Equipment (Main body and surroundings) Do status display and warning lamps function properly?

TABLE (-Continued) Step 6 No. 4.2 5. 5.1 6. 6.1 6.2 6.3 6.4 6.5

Step 6: Process Quality Assurance Autonomous Maintenance Audit Sheets

Sheet 3 of 8

Audit points

Results

Do safety devices function properly? Visual control Are new visual controls devised? Noteworthy ideas actively revealed to other PM groups? Short remedial program Is subject selected from the six big loses? Are problems clearly identified? Targets pinpointed? No easy countermeasures taken? Are cost and effects of program reviewed? Actual figures recorded? Are preventive measures against recurrence of problems provided?

TABLE (-Continued) Step 6 No. 3. 3.1 3.2

3.3 3.4 (1) (2) (3)

Step 6: Process Quality Assurance Autonomous Maintenance Audit Sheets

Sheet 4 of 8

Audit points

Results

Step 6-1-1 Are process quality and tolerances clearly identified at each exit of equipment? Quality assurance flow diagram(QAFD) drawn? Are process quality assurance lists prepared by reviewing quality-related modifications carried out in the past steps in terms of equipment, work methods, quality control standards, visual controls and mistake proofs? Are quality assurance flow diagrams revised whenever quality related modifications of equipment or work methods take place? Process quality and relevant inspecting items in terms of initial, interim and final product: Clearly defined? Absolutely needed? Well understood? Easy to understand?

TABLE (-Continued) Step 6 No. 3. 3.1 (1) (2) (3) 3.2 3.3

Step 6: Process Quality Assurance Autonomous Maintenance Audit Sheets

Sheet 5 of 8

Audit points

Results

Step 6-1-2 Quality standards, inspecting items and criteria, and corrective actions to be taken when problems occur in terms of initial, interim and final product: Well observed? Easy to understood? Can deviation be detected at a glance when problems occur? Can everyone accurately and promptly inform relevant departments when quality defects occur? Are quality standards, inspecting item and criteria corrective actions, visual controls and mistake proofs sufficiently improved?

TABLE (-Continued) Step 6 No. 3.4 3. 3.1 3.2 (1) (2) (3) (4) (5)

Step 6: Process Quality Assurance Autonomous Maintenance Audit Sheets

Sheet 6 of 8

Audit points

Results

Are all quality-related documents revised after any kind of modification? Step 6-1-3 Are past outflows of defective products accurately classified in accordance with given criteria? Preventive measures against outflows of defective product and inspecting items: Clearly defined? Absolutely needed? Well understood? Well observed? Easy to observe? Can outflows of defective products be detected at a glance when they occur?

TABLE (-Continued) Step 6 No. 3.3 3.4 3.5 3. 3.1 3.2 (1) (2) (3) (4) (5)

Step 6: Process Quality Assurance Autonomous Maintenance Audit Sheets

Sheet 7 of 8

Audit points

Results

Can everyone accurately and promptly inform relevant departments when defective products flow out? Are preventive measures against outflows of defective product and inspecting items sufficiently improved? Are all quality related documents revised after any kind of modification? Step 6-1-4 Are handling procedures for defective or quality products carefully assessed? Handling procedures for defective or quality products: Clearly defined? Well understood? Well observed? Easy to observe? Can deviation be detected at a glance when products are handled improperly?

TABLE (-Continued) Step 6 No. 3.3 3.4 3.5 3. 3.1 3.2 3.3 3.4

Step 6: Process Quality Assurance Autonomous Maintenance Audit Sheets

Sheet 8 of 8

Audit points

Results

Can everyone accurately and promptly inform relevant departments when products are handled improperly? Are handling procedures for defective or quality products and inspecting items sufficiently improved? Are all quality related documents revised after any kind of modification? Step 6-1-5 Is process automatically shut down whenever quality defects occur? Is alarm message or display issued whenever quality defects occur? Can everyone immediately detect when defective product is manufactured? Are mistake proofs, alarm displays and visual controls completely installed and improved further?

6. Three key points for successful small group activities Action board Meeting → meeting report of the small group activity One point lesson Three items the basic knowledge case study of troubles case study of improvement

It shows the history ofthe activities very well.

The activity bulletin board is your face ! your heart ! your power !

This is the realactivity bulletin board.

7. Roles of operators and maintenance people

Roles of operators and maintenance people Target

M ethods

Norm al operation

Daily m aintenance

M aintenance activities

Activities Prevent Deterioration

M easure Deterioration

Allocation Restore Equipm ent

Proper operation

○

Setup/adjustm ent

○

Cleaning・Detecting and correcting hidden faults

○

Lubrication

○

Tightening bolts and nuts

○

Conditions ofuse,daily deterioration check

○ M inor servicing

Periodic m aintenance

O perators M aintenance

Periodic inspection

○ ○

○ ○

Periodic testing Periodic servicing

○

Overallequipm ent effectiveness at least 85%

Breakdown m aintenance

Im proving reliability Im provem ent activities

○

Trend testing

Im provem ent activities

Rapid discovery ofabnorm alities, prom pt and accurate reporting

○ ○

Repair breakdowns Strengthen

○

○

Reduce load

○

○

Increase precision

○

○

○

○

Develop condition m onitoring

Im proving m aintainability

○

Non-routine servicing

Im prove testing procedures

○

Im prove servicing procedures

○

Im prove servicing quality

○

Figure Classification and Allocation of Maintenance Tasks

Appendix ３ Examples of One Point Lessons

436

X

One-Point Lesson Theme: V-belt

1.

Basic Knowledge

2.

Problem Case Study

3.

Improvement Case Study (check one)

1.

Do not use V- bel t when i t t ouches t he base

2.

Do not i gnor e ver t i cal shaki ng of VAdj us t t ens i on and c ent er of pul l ey ver t i cal shaki ng i s caused by cent er f r i ct i on l ooseni ng f r i ct i on

Yar dst i ck f or r el at i onshi p bet ween t ensi on and The V- bel t i s dr i ven by t he t r ansmi ssi on of t he wedge t hat cut s i nt o t he si de of t he Vpul l ey. When t he V- bel t t ouches t he sur f ace, t he ef f ect of t he wedge i s l ost and sl i ppi ng occur s Written by: Location:

Reference #

437

X

One-Point Lesson Theme: Ai r Cl ut c h: St r uc t ur ed Di agr am and Oper at i on

Thi s dr y si ngl e- pl at e ( f r i ct i on) t ype cl ut ch conver t s el ect r omagnet i c f or ce i nt o pneumat i c pr essur e and i s consi der abl y heavi er t han an el ect r omagnet i c cl ut ch. Written by: Location:

1.

Basic Knowledge

2.

Problem Case Study

3.

Improvement Case Study (check one)

Oper at i on • The f l ywheel ( 13 i s a V- pul l ey whi ch r ot at es al ong wi t h t he cl ut ch di sk ( 1) . • At t ached t o t he cl ut ch housi ng ( 10) secur ed t o t he f l ywheel ar e a pr essur e di sk ( 4) [ suppor t ed by a gui de key ( 3) ] , a di aphr agm ( 6) and a r ot ar y connect i on ( 9) , et c. • When t he ON but t on i s pushed, ai r swi t ched by an el ect r omagnet i c val ve ent er s t he di aphr agm ( 6) t hr ough t he r ot ar y connect i on ( 9) , swel l i ng t he di aphr agm and pr essi ng agai nst a cl ut ch di sk ( 1) suppor t ed by a dr i ve shaf t ( 11) and f r i ct i on al ong t he cl ut ch f aci ng ( 2) t r ansmi t s r ot at i onal f or ce t o t he dr i ve shaf t and br i ngs down t he sl i de. • When t he sl i de r eaches t he upper dead poi nt , t he ai r shut s Reference # of f and escapes f r om t he di aphr agm. A r et ur n spr i ng causes t he pr essur e di sk t o

438

One-Point Lesson Theme: Ai r Cl ut c h: Fai l ur es and Mal f unc t i ons I ns pec t i on Poi nt s Phenomenon 1. Sl ow dr i ve shaf t r ot at i on ( sl i ppi ng) 2. Rot at i on not t r ansmi t t ed

3. Odd noi ses

Cause Measur es 1. Wor n scr at ched 1. Repl ace l i ni ng br ake f aci ng 2. I nvent or y and 2. Dr op i n ai r r epai r ai r l eaks pr essur e 1. No ai r comi ng 1. I nvent or y and r epai r 2. Br oken el ect r i cal di aphr agm f ai l ur es 1. Bear i ngs out of oi l , wor n or damaged 2. Spl i ne wear

4. Vi br at i on

5. Heat

Written by: Location:

2. Repl ace 1. Check oi l ; r epl ace 2. Repai r or r epl ace

3. Loose mount i ng 3. Ti ght en, st op bol t s 1. Wor n or 1. Repl ace damaged 2. Repai r or bear i ngs r epl ace 2. Spl i ne wear 3. Ti ght en, st op 3. Loose mount i ng bol t s 1. Di sk sl i ppage 1. Adj ust or Reference # r epl ace 2. Bear i ng wear 2. Repl ace

X

1.

Basic Knowledge

2.

Problem Case Study

3.

Improvement Case Study (check one)

I mpor t ant I nspect i on Poi nt s 1. Any unusual noi ses, vi br at i on, heat ? 2. No wobbl e i n r ot at i on? 3. I s f r i ct i on agai nst f aci ng appr opr i at e? - - check st r oke 4. Ar e al l mount i ng bol t s appr opr i at el y t i ght ? - - appl y/ check r egi st r at i on mar ks 5. Any ai r l eaks i n t he r ot ar y connect i on?

439

X

One-Point Lesson Theme: How t o Mar k Nut s and Bol t s

1.

Basic Knowledge

2.

Problem Case Study

3.

Improvement Case Study (check one)

Don’ t t ouch bol t s wi t h RED pai nt - - onl y mai nt enance checks/ t i ght ens

Bol t s checked dur i ng i nspect i on - - add whi t e mat ch mar ks af t er bol t pr oper l y secur ed Mat ch mar ks shoul d cover t op, si de and bot t om l i ke t hi s:

Put dot on t op of bol t , l i ke t hi s:

Written by: Location:

Reference #

440

X

One-Point Lesson Theme: Pneumat i c Dev i c es : Ai r Fi l t er

1.

Basic Knowledge

2.

Problem Case Study

3.

Improvement Case Study (check one)

St r uct ur al Di agr am

Basi c Funct i ons ➊ Pr ovi des cl ean dr y ai r , f r ee of moi st ur e, oi l and dust ➋ Pr ovi des Cent r i f ugat i on, separ at i on and dust r emoval f unct i ons f or use i n pneumat i c aut omat i c cont r ol ci r cui t s ➌ Def l ect or s spi n compr essed ai r ent er i ng at I N; as condensat e and cont ami nant s ar e cent r i f uged t o t he i nner wal l , t hey col l ect i n t he bowl

Funct i ons of I ndi vi dual Par t s 1. Def l ect or 2. Fi l t er el ement 3. Baf f l e pl at e 4. Dr ai n val ve

I mpar t s cent r i f ugal f or ce t o compr essed ai r Removes mi cr oscopi c par t i cl es f r om compr ess ed ai r Pr event s backf l ow of condensat e and cont ami nant s Al l ows r emoval of condensat e, et c.

5. Et c. Written by: Location:

Reference #

441

One-Point Lesson Theme: Ai r Fi l t er : Fai l ur es and Mal f unc t i ons Phenomenon 1. Cont ami nant s come out of OUT por t

2. Ext er nal ai r l eak

3. Excessi ve dr op i n pr essur e

4. For ei gn mat t er comes out of OUT por t

5. Damaged bowl Written by: Location:

X

1.

Basic Knowledge

2.

Problem Case Study

3.

Improvement Case Study (check one)

Cause

Measur es

1- 1 Negl ect ed cont ami nant r emoval 1- 2 Fl ow t hr ough f i l t er exceeds pr escr i bed vol ume 2- 1 Poor O- r i ng ( 5) seal 2- 2 Bad dr ai n val ve ( 9) 3- 1 Fi l t er el ement ( 2) cl ogged 3- 2 I mper f ect el ement ( 2) seal 4- 1 Damaged f i l t er el ement 4- 2 I mper f ect seal el ement

1- 1 Remove cont ami nant s r egul ar l y each shi f t

5- 1 Used i n at mospher e Reference # cont ai ni ng an or gani c sol vent

1- 2 Use appr opr i at e f l ow/ f i l t er 2- 1 Repl ace O- r i ng 2- 2 Repai r or r epl ace 3- 1 Cl ean or r epl ace 3- 2 Repl ace wi t h l ar ger one 4- 1 Repl ace f i l t er el ement 4- 2- 1 Repl ace seal ant 4- 2- 2 Repai r or t i ght en el ement hol der 5- 1 Use met al bowl

442

X

One-Point Lesson Theme: Fi l t er

1.

Basic Knowledge

2.

Problem Case Study

3.

Improvement Case Study (check one)

Fi l t er Fi l t er OK I ndi cat or down

Written by: Location:

Fi l t er Cl ogged I ndi cat or in up posi t i on

Reference #

443

X

One-Point Lesson Theme: Your Tool s and How t o Us e Them

1.

Basic Knowledge

2.

Problem Case Study

3.

Improvement Case Study (check one)

St r uct ur e Hand Oi l er

Basi c Funct i ons

Pr oper Handl i ng

Nozzl e- capped pol yet hyl ene cont ai ner

Pl ace t i p of nozzl e f aci ng down at oi l i ng si t e and pr essOt her exampl es: Oi l can • l i ght l y on Oi l can cont ai ner • Funnel Pump oi l can • Pi st ol - t ype oi l er Do not cr ush Al l used f or • Lever - t ype gr ease gun t i p hand oi l i ng • Aut omat i c gr ease syst ems, et c Used wi t h l ow Keep cl ean and vi scosi t y oi l cl ear of di r t and dust Desi gnat e and use speci f i c cont ai ner s f or di f f er ent t ypes of oi l

Written by: Location:

Reference #

444

One-Point Lesson Theme: I mpr ov ement of Unr eadabl e Oi l Lev el Gauge on Br ak e

X

1.

Basic Knowledge

2.

Problem Case Study

3.

Improvement Case Study (check one) oi l hol e

Current Situation The oi l gauges on a conveyor br ake and a gear mot or l can’ t be checked because t hey ar e hi dden behi nd pul l eys l ar e di scol or ed and cl oudy Spar es ar e di f f i cul t t o get and har d t o i nst al l , so t he gauges ar en’ t checked and l ubr i cat i on i s l ef t unmanaged. Description of Improvement We at t ached a commer ci al l y avai l abl e oi l gauge t o a shor t pi pe i nser t ed i n t he dr ai n hol e. Thi s made i t easy t o check t he oi l l evel .

ol d oi l gaug e

oi l dr a gauge i n hol e i mpr oved oi l gauge

ni ppl e T

bl i nd val ve ( dr ai n hol e) and cl eani ng hol e shor t pi pe ( l ong enough t o r each dr ai nage cont ai ner )

Key Points to Note 1. Don’ t at t ach an L- shaped oi l gauge di r ect l y t o t he dr ai n hol e; sl udge wi l l accumul at e i n t he bend and event ual l y cl og t he l evel . l I nst ead, at t ach t he oi l gauge t o a dr ai n pi pe i nser t ed i n t he dr ai n hol e. Thi s way, any sl udge can be f l ushed out . 2. Per m anent l y mar k t he new oi l gauge wi t h t he same l evel as t he ol d gauge. Written by: Location:

Reference #

445

X

One-Point Lesson Theme: I s t he hy dr aul i c uni t wor k i ng nor mal l y ? ( par t 2) If af t 1, But

machi ne cycl es r emai er cl eani ng out t he you need t o move t o her e ar e some quest 1.

2.

n sl ow at l ow t hydr aul i c uni t t he next l evel i ons t o ask bef

1.

Basic Knowledge

2.

Problem Case Study

3.

Improvement Case Study (check one)

emper at ur es even as descr i bed i n Par t of count er measur es. or e you do:

What t ype of hydr aul i c par t s ar e used i n t he uni t ? Does t he uni t conf or m t o t he hydr aul i c r out i ng di agr am? ( Check pi pe di amet er s, f or exampl e. )

Ol der f l ow cont r ol val ves ( 20- 50 l / mi n. or l ess) ar e t ypi cal l y not equi pped wi t h t emper at ur e compensat or s. As a r esul t , changes i n hydr aul i c f l ui d vi scosi t y due t o t emper at ur e f l uct uat i ons may cause f l ui di t y t o var y by 10 t o 20 per cent . I n envi r onment s wher e such cycl e t i me f l uct uat i ons pose a pr obl em, t r y i nst al l i ng a f l ow cont r ol l er equi pped wi t h a t emper at ur e compensat or mechani sm. Written by: Location:

Reference #

446

One-Point Lesson Theme: An Ex ampl e of Res t or at i on

X

1.

Basic Knowledge

2.

Problem Case Study

3.

Improvement Case Study (check one)

Cycl e di agr am

An Exampl e of Rest or at i on

Pr obl em

Tr eat ment

The mi cr oadj ust m ent of t he val ve t hat adj ust s t he f i ni sh f eed speed di dn’ t wor k.

The cam pl at e had devel oped r i dges, and t he val ve coul d not adj ust t he f l ow cor r ect l y. We r epl aced t he cam pl ati se. Ther e was debr adher i ng t o t he t i p of t he speed cont r ol val ve.

The l oadi ng speed was sl ow and t he nongr i ndi ng per i ods wer e t oo l ong. Written by: Location:

Reference #

We t ook t he val ve apar t and cl eaned it.

447

Basic Information Lesson - Sample 1 This example of an information lesson makes extensive use of simple graphics to explain which things co ntaminate hydraulic fluid. Graphics often clarify concepts and make them easier to remember. The lesson would be delivered orally, with this sheet serving as a visual aid. Afterwards, this sheet will be made avail able for reference. The information will eventually be incorporated in the standard procedures. •

Cont ami nat i on of Hydr aul i c Fl uiHeat d Wat er

Di r t & Gr i me

Rust

Machi ne i n oper at i on ( wi t h cut t i ng Rubbed- of f par t i cl es debr i s, sand, Vi br at i onet c. )

I ce f or mat i on

Oi l oxi des

Ai r

Pai nt

New l ubr i cant suppl y sc hed Seal i ng t ape

448

•

Basic Information Lesson - Sample 2

This is a continuation of the one-point lesson on hydraulic contaminati on shown on the prior page. Hydr aul i c Devi ce and Cont ami nat i on

Because t he hydr aul i c devi ce has such nar r ow i nt er nal cl ear ance Cont ami nat i on i s t he No. 1 enemy of hy dr aul i c equi spaces, i t cannot t ol er at e much cont ami nat i on and st i l l oper at e lAr e any unnecessar y hol es bei ng l ef t i n t he equi ef f i ci ent l y. l Speci f i ed I s dr ai n pi pe pr oper l y i nser t ed i nt o t ank? l cl ear ance I s l i d on oi l suppl y hol e f ast ened secur el y? Sect i on Exampl e r ange ( mi cr ons) Car r y out i mpr ovement measur es at al l l ocat i ons wher e cont ami nant s may ent er t he equi pment . Poppet val ve 13 　 40

Vane pump ( vane si des)

5 　 13

Val ve ( spool & sl eeve)

1 　 23

Gear box ( gear wheel & 0. 5 　 5 si de pl at e)

449

One-Point Lesson Theme: How t o adj us t ai r pr es s ur e on t he Fy c on Fi ni s h Appl i c at or det ai l of pr essur e gauge on r egul at or

l

l

l

If pai If pai

t he pr ocess i nt ed sect i on t he pr ocess i nt ed sect i on

s of s of

i n cont r ol , t he needl e wi l l be poi nt i ng i nsi de t he GREEN t he pr essur e gauge. out of cont r ol , t he needl e wi l l be poi nt i ng i nsi de t he RED t he pr essur e gauge.

I f t he pr ocess i s out of cont r ol ( oper at i ng i n t he RED ar ea of t he

450

Grease Fittings

1.

2. 3.

Gr ease f i t t i ng shoul d al ways be si l ver ; Never pai nt over one! Do not st r i ke f i t t i ng wi t h anyt hi ng. I f t he f i t t i ng has dent s or wi l l not accept gr ease, r epl ace i t !

451

One Point Lesson: Red Tagging •

Any time you find an unneeded item, Red Tag It!

1. Wr i t e your name

2. Recor d t he dat e Name: Tom F. Date: 8/21/99 Item: Electric Drill

3. Recor d l ocat i on of f ound i t em

Location of Item: Door Assembly Area Floor Reason for Red Tagging: Broken handle Suggested Disposition: Discard, not fixable 4. Recor d r eason f or t aggi ng

5. Make suggest i o n f or r esol ut i o n

Fi r st , wr i t e a Red Tag and at t ach i t , f ol l owi ng t he di spl ayed st eps. Then, br i ng t he i t em t o t he Red Tag Hol di ng Ar ea.

u u

452

One-Point Lesson Theme: The Two- Bi n Sy s t em f or I ns t ant Mai nt enanc e Par t s

X

1.

Basic Knowledge

2.

Problem Case Study

3.

Improvement Case Study (check one)

Us e a cont ai ner di vi ded i nt o t wo bi ns; st ar t wi t h bot h s i des f Post t he kanban f r om si de A and begi n usi ng par t s.

Put a kanban ( or der car d) i n each si de. Sl i de t he l i d t o cover si de B.

The kanban wi l l pr ocur e mor e par t s f or si de A. When t he par t s on si de A ar e used up, sl i de t he l i d and begi n usi ng si de B par t s. Post t he kanban f or si de B.

Par t # 2008010018- 0 Name: Gui de pi n Or der quant i t y : 50 uni t s When t he or der ed par t s ar r i ve, put t hem i n si de A Cont i nue t o r epeat st eps Written by: Location:

and Reference #

453

X

One-Point Lesson Theme: Hy dr aul i c Power Uni t I ns pec t i on

1.

Basic Knowledge

2.

Problem Case Study

3.

Improvement Case Study (check one)

Pur pose of I nspect i on

The hydr aul i c power uni t pr ovi des power t o t he ent i r e hydr aul i c syst em. Even i f you use t he r i ght amount of oi l , l ocal oi l shor t ages, cl ogged f i l t er s, or ot her causes may r esul t i n cavi t at i on. * Thi s can cause pr obl ems ( noi se, cor r osi on, pr essur e f l uct uat i ons, or vi br at i on) i n hydr aul i c devi ces t hr oughout t he syst em, so dai l y checks ar e W hat t o Check and How essent i al . Dai l y checks can be per f or med dur i ng oper at i on and consi st of l ooki ng f or abnor mal i t i es usi ng t emper at ur e and ot her gauges, as wel l as t he human senses of si ght , hear i ng and t ouch. pr essur Bad Exampl e e gauge 1.

mot or

oi l r et u pump r n

oi l l evel gauge suct i on f i l t er

Check Oi l Vol ume

When t he oi l dr ops bel ow t he l ower i ndi c at or l i ne of t he oi l v ol ume gauge, t he s uct i on f i l t er pul l s i n ai r and ai r ent er s t he r et ur n t ube. Add oi l when t hi s occ ur s . 2. Check Suc t i on Fi l t er A cl ogged s uct i on f i l t er c aus es ai r t o ent er t he sys t em. Remove t he f i l t er t o check. I f cont ami nat i on i s l i ght , wash wi t h det er gent oi l and r epl ac e t he f i l t er . Repl ace t he f i l t er i f cont ami nat i on i s heavy. Consi der us i ng a bar r i er t o k eep

454

Good Exampl e pr ess ur e gauge

oi l r et u rn

mot or

cont ami nant s

Written by:

bar r i er

pump

3. Check Suct i on Joi nt s,

Gasket s, and Pi pes Ti ght en any l oose j oi nt s. Repl ace any det er i or at ed gasket s. Check f or hai r l i ne cr acks i n pi pes and r epai r or r epl ace i f any ar e f ound.

* When a l ocal dr op i n oi l pr essur e occur s, di ssol ved ai r escapes i n t he f or m of bubbl es. When r api d pr essur e i s t hen appl i ed, t he ai r has no t i me t o r edi ssol ve and t he ai r becomes super compr essed and causes noi se as i t st r i kes a sur f ace. Thi s i s cal l ed cavi t at i on.

Reference #

Location:

455