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To PREVENT EQUIPMENT DETERIORATION TO MAINTAIN EQUIPMENT IN OPTIMAL CONDTION TO ESTABLISH BASIC EQUIPMENT CONDITION TO ELIMINATE EQUIPMENT FAILURE TO MAKE OPERATOR EQUIPMENT COMPETENT TO ELIMINATE Quality Defects TO ELIMINATE COST LOSSES
Mr. Deepak Sahoo Consultant
Corrective Maintenance Prevent errors by improving operability Improve Maintainability & Repair Quality Improve safety & Reliability
Establish Basic Condition Cleaning : Eliminate all dust & Dirt Lubricating : Keep lubricants clean and replenished Tightening : Keep nuts & bolts secure
Mr. Deepak Sahoo Consultant
Daily Prevention
Early treatment
Prevents deterioration
Daily maintenance (lubricate, clean, adjust, inspect
Repair deterioration
Make preventive repairs (advance replacement)
Preventive Maintenance
Breakdown maintenance
Corrective maintenance Improvement of maintainability Improve Prolong equipment life Eliminate maintenance Reduce maintenance hours Improvement of reliability
Maintenance prevention
Design which does not need maintenance
CLASSIFICATION OF DEFECTS
Physical latent defects The defects which are left unattended since they are not physically exposed to naked eyes Psychological latent defects Defects which are left unnoticed due to insufficient knowledge and education of operators or maintenance people
1. Defects which can not be visually observed unless the equipment is dismantled
2. Defects which can not be visually noticed due to improper installation location of equipment
3. Defects which are likely to be ignored since they are covered with dust or they are heavily soiled
1.MINOR FLAWS
1.MINOR FLAWS :
Contamination Dust, Dirt, powder, oil, grease, rust, paint Damage Cracking, crushing, deformation, chipping, bending, Play Shaking, falling out, tilting, eccentricity, wear, distortion, corrosion, Slackness Belts, Chains
Abnormal Phenomenon Adhesion Unusual noise, overheating, Vibration, strange smells, discoloration, incorrect pressure or current Blocking, hardening, accumulation of debris, peeling, malfunction
Mr. Deepak Sahoo Consultant
3. INACCESSABLE PLACES
Cleaning Checking Machine construction, Covers, Layout, footholds, Space Construction, Covers, Layout, footholds, Instrument position and Orientation, Operating Range display
Lubricating Position of lubricant inlet, construction, height, footholds, lubricant outlets, space Tightening Operation Covers, Construction, Layout size, Space Machine layout, Position of valves, Switches and leavers, Footholds
Adjustment Position of pressure gauges, thermometers, flow meters, moisture gauges, vacuum gauges, etc.
Mr. Deepak Sahoo Consultant
4. CONTEMINATION SOURCES
Product Raw materials Lubricants Gases Leaks, Spills, Spurts, Scattering, Overflow Leaks, Spills, Spurts, Scattering, Overflow Leaking, Spills, Seeping oils, Hydraulic fluids, Fuel oils, etc. Leaking compressed air, gases, steam, vapors, exhaust fumes, etc. Leaking water, Hot, Cold, half finished products, Waste water, Leaking supply lines etc. Flashes, cuttings, packaging materials, and non conforming products. Contaminants by people & Forklifts, Infiltration through cracked walls, broken windows etc.
Mr. Deepak Sahoo Consultant
Liquids
Scrap Others
7. UNSAFE PLACES
Floors Steps Lights Rotating machinery Lifting Devices Others Unevenness, cracked, holes, projections, peeling, wear of steel chucker plates, slipping. Too steep, irregular, slipping, missing handrails, etc. Dim, out of position, dirty or broken covers, no explosion proofing, etc. Displaced, fallen oil or broken covers, not safe for emergency, missing emergency stop devices Wires, hooks, brakes and other parts of cranes and hoists etc. Special substances, solvents, toxic gases, insulating materials, danger signs, protective clothing etc.
Mr. Deepak Sahoo Consultant
Preparation
Z
E PREPARE A CLEANING & LUBRICATION MAP
R
O S T E
ARRANGE TOOLS
ARRANGE RED & WHITE TAGS HISTROY OF FAILURES TRAINING ON 7 STEPS OF JISHU HOZEN TRAINING ON 7 TYPES OF ABNORMALITIES
CLEANING IS INSPECTION
Detected by..
Description of Minor defects .
Detected by..
Description of Minor defects . .. .
..
.
MAKE THE LIST OF HARD TO CLEAN, HARD TO LUBRICATE, HARD TO TIGHTEN, HARD TO INSPECT, HARD TO ADJUST RECORD CLEANING TIME CARRY OUT AUDIT ON 1ST STEP
Areas / Parts
RELAY TRAINING
Purpose of Step-2
Eliminate sources of Contamination To improve places where it is difficult to access for cleaning, lubrication, inspection Improved maintainability of Equipment Enable Learning in tackling Equipment Kaizen
STEP 2
CLITA
COUNTERMEASURES AGAINST SOURCES OF CONTAMINATION MAKE APPROACH EASY FOR CLITA
Reduce need to
(Frequency)
approach
Improve Accessibility
Mr. Deepak Sahoo Consultant
Easy to clean
SOURCE OF CONTAMINATIONS
Easy to lubricate
Localised gaurds
The return oil flow from the feed drive gears splash and spread all around the open space inside the machine there by getting contaminated. To avoid the contamination, the return oil flow is channalised from the feed drive gears directly to the lubrication tank
Mr. Deepak Sahoo Consultant
Before
Difficult to Lubricate the oil to gear box
After
Easy to Lubricate the oil to gear box
Mr. Deepak Sahoo Consultant
Easy to Inspect
THEME:
To reduce Inspection time
LOSS NO. 8A
KAIZEN
LOSS STRUCTURE: Inspection Time Reduction IDEA: To bring the pressure gauge for K.O. system outside the machine for easy inspection COUNTERMEASURE: Before After
MACHINE:
Inspection is very difficult and taking more time in the pressure gauge for K.O. system
Difficult to Inspect
ANALYSIS:
WHY 1 Problem : Inspection is difficult WHY 2 Pressure gauge kept inside the machine
15
RESULT:
Sec. 30 sec / change
30
HORIZONTAL DEPLOYMENT :
Inspection is very difficult and it is taking moretime in pressure gauge for K.O. system
Better
No of Areas Identified
2 sec / Day
0
: 5 Nos.
Implemented : 5 Nos.
Before
After
Purpose of Step-3
Continuously Maintaining and Management of Basic equipment conditions, (I.e. Cleaning, Lubrication, Retightening) Enhancing Equipment Reliability & Maintainability Preparing standards that can be followed easily Ideas for Visual Improvement
Feedback
Audit Passed
STEP 3
STANDARDS FOR CLEANING, LUBRICATING AND TIGHTENING STANDARDS ARE MADE BY OPERATORS THEMSELVES WITH GUIDENCE BY PM
Cleaning activities :
Lubrication activities :
Inspection activities :
Criteria
Sub Assembly
Where
What
How
Cleaning
Steel belt
20 Sec
Operator
Quality defect
Lubrication
30 Sec
Operator
Equipment failure
5 Sec
Operator
UNSAFE
VISUAL CONTROLS
Activity
Symbol
Tools
CLEAN
LUB
INSPECTION
I S NOC
Mr. Deepak Sahoo Consultant
Purpose of Step-4
Bringing up equipment consciousness in the process of measuring & restoring deterioration. To understand structures, functions & principles of equipment & learn their optimal conditions to thoroughly check principal mechanisms & parts of the equipment
Lubrication system
Pneumatic System Equipment Safety
Additional Items: Specific to the Equipment Preparation of text for General Inspection Education & Training Schedule Planning for General Inspection Education & Training
Mr. Deepak Sahoo Consultant
Inspection skill Check Autonomous Audit & Application for receiving diagnosis
Implementation of Audit Solutions to the Items Pointed out
Inspection skill Check Autonomous Audit & Application for receiving diagnosis
Implementation of Audit Solutions to the Items Pointed out
Initial Clean-up ( Cleaning is Inspection) ( Cleaning with meaning) (Doing with purpose)
Taking countermeasure for forced deterioration and improving hard to access area Preparing tentative standards for cleaning and lubrication
Learn how to operate the equipment with the required accuracy and how to evaluate the product quality Study the mechanism and functions of equipment and machines Familiarize with the concept of equipment maintenance and improvement and with how to put the idea into practical realization
1
1 Initial clean-up