JISHU HOZEN- AUTONOMOUS MAINTENANCE

Loss Structure During Production Activities (16 Major Losses)

5 Major Losses Preventing Efficiency of Manpower

Operated man-hour
Waiting
instruction loss
Waiting material
loss
Equipment
downtime loss
Equipment
performance loss

Excluding manhour (Supported

by other
departments)

9. Management
loss
10. Operating
motions loss

Line
organisation manhour loss

Method/
procedures loss
Skills and morale
loss
Line organization
loss
Unautomated
system loss

Production
Man-hour
loss

11. Line organisation

loss

Defects
in manhour
loss

[Equipment Efficiency]

<Equipment>
Elapsed time

<person>
Man-hour

Loading man-hour

Duty hour

Scheduled
downtime

Scheduled
downtime
8. Breakdown loss
1. Equipment
failure loss

Loading time

2. Set-up loss

Net operational
Man-hour

Operating time

Downtime
loss

3. Cutting blade and

jig change loss
4. Start - up loss

Effective
man-hour

Net Operating
time

Valued man-hour
Valued
(man-hour for operating
time
turnout)

Performance
loss

Defects
quality
loss

Other downtime loss

5. Minor stoppage &
idling loss
6. Reduced speed
7. Defects and
rework loss

12. Logistics loss

<Energy>

Cleaning
checking
Waiting
instruction
Waiting
materials
Waiting
personnel
distribution
Quality
confirmation
(Adjustment of
measurement)

8 Major Losses Preventing Efficiency of equipment

[Manpower Efficiency]

<Materials>

13. Measurement and

adjustment loss

Loading time

Input energy
Start-up loss

Overload loss

15. Energy loss

Effective energy

No. of qualified
products

Weight of
qualified products

Radiation loss

Defects quality loss

Start-up loss
Cutting loss

14. Yield loss

Losses in weight
Losses in excesses
(increased commission)

16. Die and Tool loss

[Efficiency of material and energy]

3 Major Losses Preventing Efficiency of Material and Energy.

Relationship between Seven Major Losses on Equipment and

Overall Equipment Effectiveness
Equipment

Seven major losses

Calculation of overall equipment effectiveness

1.Equipment
Failure
Loading
time

Down time
losses
Speed
losses

loadingtime downtime
loadingtime

100

(e.g)

2. Set up and
adjustment

Operating
time

Net
operating
time

Availability =

Availability =

3. Cutting Tool
replacement
4. Startup Loss

460mins 60mins.
100 = 87%
460mins.

Performance theoretical cycletime x processedamount

=
100
efficiency
Operatingtime
(e.g)

5. Idling and minor

stoppage
6.Reduced speed

Performance 0.5mins./unit x 400units

=
100 = 50%
efficiency
400mins

Rateof quality processedamount - defectamount

=
100 = 100
products
processedamount

Defect
losses

(e.g)

Valuable
operating
time

7. Defectives
and rework

Rateof quality 400units - 8 units

=
100 = 98%
products
400units

Overallequipment
= Availability x Performance Rateof quality products
effectiveness
efficiency
(e.g.) 0.87 0.50 0.98100 = 42.6%

Autonomous Maintenance
Autonomous mean Self Governed
So, Autonomous maintenance is self
governed maintenance system
Japanese call it Jishu Hozen

Maintenance Two Expects

1. Sustainment Activities
Preventing and correcting

2. Improvement Activites
Prolonging the working life of the
equipment, reducing the time spent on
maintenance, and eliminating the need for
maintenance

Measures for Sustaining

Correct operation
Routine maintenance
Periodic maintenance
Predictive maintenance

Measures for Improvement

Corrective maintenance
Improve reliability and maintainability

Maintenance prevention
Designing out the need for maintenance

Autonomous Maintenance

Individual preserving ones own equipment

Significant change from early theory of

I Manufacture - You Repair or I Make - You Fix

Theme is
If equipment changes - people will change
If people change - shop will change.

Operation and Maintenance are like wheels on both sides of a car

I can decide, I can do, I am empowered to do.

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Change the Bitter Complaints

which come from........
Production

Maintenance

Maintenance does not know

its job

They (Production) dont

know how to operate

They take too long to fix the

equipment

This equipment is so
antiquated, n wonder it
breaks down

We get lot of repairs so we

dont have ample to do a
real corrective action and
are forced to only do
disposition

We are too busy to do vital

daily checks

We repair the standards, but

they dont do the checks

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Daily care of our Body (Brushing, Bathing, Cleaning.....), We do

Ourselves. We only go to the Doctor (Specialist) for treatment
when we are ill.

Do we have similar approach for our machine (Cleaning, Oiling food, tightening) Do we allow a Forced Deterioration of our body
or sustain Basic Condition? Why we have different approach for
our Machine, calling the doctor (maintenance - specialist) for
every problem & banking on him to take care of machine.

Detect and Sense Abnormalities

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FAILURE

Natural Deterioration
(Inherent lifetime)

Accelerated Deterioration
(Artificially induced)

Extend Lifetimes

Eliminate Causes
Establishment for Basic
Conditions

Corrective Maintenance

Prevent errors by improving

operability

Improve maintainability and

repair quality

Improve safety and reliability

Cleaning : eliminate all dust

and dirt

Lubricating : Keep lubricants

clean and replenished

Tightening : Keep nuts and

bolts secure

Establishing Basic Equipment Conditions Eliminates Causes of

Accelerated Deterioration
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Relationship Between Forced Deterioration and Losses

Example of Forced Deterioration
Due to Inadequate Cleaning
1. Cause of failure

Contamination by dirt or fallen matter in rotating parts, sliding

parts, air and oil pressure systems, electrical control systems,
sensors, etc. causes a drop in accuracy, misoperation or a
failure due to wear, jamming, resistance, poor electrical
conductivity, etc.

2. Cause of quality

Direct contamination by foreign matter in products and

misoperation of equipment results in quality defects.

3. Cause of reduced
life

Waste and dirt makes it difficult to inspect for looseness,

cracks, play and out-of-oil conditions, resulting in forced
deterioration.

4. Cause of speed
losses

Dirt increases frictional resistance and sliding resistance

resulting in speed losses such as decreased performance and
idling.

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JH Step-1 (Initial Clean up)

Uncover to Discover

Discover by Cleaning

Cleaning for Inspection

Cleaning with Meaning

Inspection for Identification of Abnormalities/Malfunction Repair.





Cleaning
Lubrication
Inspection

- Remove dust, dirt, stains, Defective /Unnecessary Parts etc.

- Restore basic conditions for lubrication by tagging.
- Identify & Tag Source of contamination/potential defects,
malfunctions, problems, unsafe conditions/acts etc.

Improvements for ease of

Cleaning, Lubrication & Inspection and
How the work area should be.

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Abnormality
'Abnormality' is condition of the machine which is not in the best and perfect
condition and leads to a potential breakdown of machine, generation of
defects.
i Leakage of air, water, oil etc.
i Loose hanging wires, Improper electrical panel insulation.
i Loose fitment of control panel covers, switches, hydraulic tanks etc.
i Radiation/ heat loss due to improper insulation
i Accessories not working hence bypassed
i Spreading of swarf, sand, paint, oil, dust & Splashing of coolant etc.
i Abnormal noise, vibration, harshness corroded elements, parts etc.
i Grouted bolts, Nails on floor, sharp edges of racks/panels etc.

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Sample Manual on Exposing Seven

Types of Abnormality
Abnormality

Examples

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 phenomena

Unusual noise, overheating, vibration,

strange smell, discoloration, incorrect
pressure or current

Adhesion

Blocking, hardening, accumulation of

debris, peeling, malfunction
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Sample Manual on Exposing Seven Types of

Abnormality (Cont.)
Abnormality

Examples

2. Unfulfilled Basic Conditions

Lubrication

Insufficient, dirty, unidentified,

unsuitable, or leaking lubricant

Lubricant supply

Dirty, damaged, or deformed lubricant

inlets, faulty lubricant pipes

Oil level gauges

Dirty, damaged, leaking ; no indication

of correct level

Tightening

Nuts and bolts slackness, missing,

cross-threaded, too long, crushed,
corroded, washer unsuitable, wing nuts
on backward

17

Sample Manual on Exposing Seven Types of

Abnormality (Cont.)
Abnormality

Examples

3. Inaccessible Places
Cleaning

Machine construction, covers, layout, footholds,

space

Checking

Covers, construction, layout, instrument position

and orientation, operating - range display

Lubricating

Position of lubricant inlet, construction, height,

footholds, lubricant outlet, space

Tightening

Covers, construction, layout, size, footholds, space

Operation

Machine layout: position of valves, switches, and

levers: footholds

Adjustment

Position of pressure gauges, thermometers,

flowmeters, moisture gauges, vacuum gauges, etc.
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Sample Manual on Exposing Seven Types of

Abnormality (Cont.)
Abnormality
4. Contamination Sources
Product
Raw materials
Lubricants
Gases
Liquids

Scrap
Other

Examples
Leaks, spills, spurts, scatter, overflow
Leaks, spills, spurts, scatter, overflow
Leaking, spills, and seeping lubricating oils,
hydraulic fluids, fuel oil, etc.
Leaking compressed air, gases, steam, vapors,
exhaust fumes, etc.
Leaking, spill and spurting cold water, hot water,
half - finished products, cooling water, waste
water, etc.
Flashes, cuttings, packaging materials, and
nonconforming product
Contaminants brought in by people, fork-lift
trucks, etc. and infiltrating through cracks in
buildings
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Sample Manual on Exposing Seven Types of

Abnormality (Cont.)
Abnormality

Examples

5. Quality Defect Sources

Foreign matter

Inclusion, infiltration, and entrainment of rust,

chips, wire scraps, insects, etc.

Shock

Dropping, jolting, collision, vibration

Moisture

Too much, too little, infiltration, defective

elimination

Gain size

Abnormalities in screens, centrifugal

separators, compressed - air separators, etc.

Concentration

Inadequate warming, heating, compounding,

mixing, evaporation, stirring, etc.

Viscosity

Inadequate warming, heating, compounding,

mixing, evaporation, stirring, etc.
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10

Sample Manual on Exposing Seven Types of

Abnormality (Cont.)
Abnormality

Examples

6. Unnecessary and Non-urgent items

Machinery

Pumps, fans, compressors, columns, tanks,

etc.

Piping equipment

Pipes, hoses, ducts, valves, dampers, etc.

Measuring instruments

Temperature and pressure gauges, vacuum

gauges, ammeters, etc.

Electrical equipment

Wiring, piping, power leads, switches, plugs,

etc.

Jigs and tools

General tools, cutting tools, jigs, molds,

dies, frames, etc.

Spare parts

Standby equipment, spaces permanent

stocks, auxiliary materials, etc.

Makeshift repairs

Tape, string, wire, metal plates, etc.

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Sample Manual on Exposing Seven Types of

Abnormality (Cont.)
Abnormality

Examples

7. Unsafe Places
Floors

Unevenness, ramps, projections, cracking,

peeling, wear (steel deckplates)

Steps

Too steep, irregular, peeling anti-slip covering,

corrosion, missing handrails

Lights

Dim, out of position, dirty or broken covers, no

safety or emergency stop devices

Rotating machinery

Displaced, fallen off or broken covers, no

safety of emergency stop devices

Lifting gear

Wires, hooks, brakes, and other parts of

cranes and hoists.

Other

Special substances, solvents, toxic gases,

insulating materials, danger sign, protective
clothing etc.
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11

Checkpoints for Nuts and Bolts

Slight Defects
Bolt Lengths
Washers

Attachment of Nuts and Bolts

Are any nuts or bolts loose?

Are any nuts or bolts missing?
Do all bolts protrude from nuts by 2-3 thread
lengths?
Are flat washers used on long holes?
Are tapered washers used on angle bars and
channels?
Are spring washers used where parts are subject
to vibration?
Are identical washers used on identical parts?
Are bolts inserted from below, and are nuts
visible from the outside?
Are devices such as limit switches secured by at
least two bolts?
Are wing nuts on the right way around?
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Lubrication Checkpoints
Lubricant Storage

Are lubricant stores always kept clean, tidy and

well-organized by through application of the 5S
principles?
Are lubricant containers always capped?
Are lubricant types clearly indicated and is
proper stock control practiced?

Lubricant Inlets

Are grease nipples, speed-reducer lubricant

ports, and other lubricant inlets always kept
clean?
Are lubricant inlets dustproofed?
Are lubricant inlets labeled with he correct type
and quantity of lubricant?

24

12

Lubrication Checkpoints (Cont.)

Oil-level Gauges

Are oil-level gauges and lubricators always kept

clean, and are oil levels easy to see?
Is the correct oil level clearly marked?
Is equipment free of oil leaks, and are oil pipes
and breathers unobstructed?

Automatic Lubricating Devices

Are automatic lubricating devices operating

correctly and supplying the right amount of
lubricant?
Are any oil or grease pipes blocked, crushed or
split?

Lubrication Condition

Are rotating parts, sliding parts, and

transmissions (e.g. chains) always clean and
well-oiled?
Are the surroundings free of contamination by
excess lubricant?
25

Transmission System Checkpoints

V-belts and Pulleys

Are any belts cracked< swollen< worn< or

contaminated by oil or grease?
Are any belts twisted or missing?
Are any belts stretched or slack?
Are multiple belts under uniform tension and all of
the same type?
Are top surfaces of belts protruding above the
pulley rims?
Are the bottoms of any pulley grooves shiny
(indicating a worn belt or pulley)?
Are pulleys correctly aligned?

Roller Chains

Are any chins stretched (indicating worn pins or

bushings)?
Are any sprocket teeth worn, missing, or damaged?
Is lubrication between pins and bushing sufficient?
Are sprockets correctly aligned?
26

13

Transmission System Checkpoints (Cont.)

Shafts, Bearings, and Couplings

Is there any overheating, vibration, or

abnormal noise due to excessive play or poor
lubrication?
Are any keys or set bolts loose or missing?
Are any couplings misaligned or wobbly?
Are any coupling seals worm? Are any bolts
slack?

Gears

Are gears properly lubricated with the right

amount of lubricant? Are the surroundings
clean?
Are any teeth worn, missing, damaged, or
jammed?
Is there any unusual noise or vibration?
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Hydraulic Checkpoints
Hydraulic Units

Heat Exchangers

Is the correct quantity of fluid in hydraulic

reservoirs, and is the correct level indicated?
Is fluid at the correct temperature? Are the
maximum and minimum permissible
temperatures indicated?
Is fluid cloudy (indicating air entrapment)?
Are all fluid inlets and strainers clean?
Are any suction filters blocked?
Are any fluid reservoir breather filters blocked?
Are all fluid pumps operating normally without
any unusual noise or vibration?
Are hydraulic pressures correct, and are
operating ranges clearly displayed?
Is any fluid or water leaking from fluid coolers or
pipes?
Are temperature differences between fluid and
water inlets and outlets correct? Are any tubes
blocked?
28

14

Hydraulic Checkpoints (Cont.)

Hydraulic Equipment

Are there any fluid leaks?

Are hydraulic devices properly secured without any
makeshift fastenings?
Are hydraulic devices operating correctly without speed
losses or breathing?
Are hydraulic pressures correct, and are all pressure
gauges working correctly (zero points, deflection)?

Piping and Wiring

Are all pipes and hoses securely attached?

Are there any fluid leaks? Are any hoses cracked or
damaged?
Are all valves operating correctly? It is easy to see
whether valves are open or shut?
Are any pipes, wires, or valves unnecessary?

29

Pneumatic Checkpoints
FRLs

Are FRLs always kept clean? Is it easy to see

inside them? Are they fitted the right way around?
Is there sufficient oil, and are the drains clear?
Is the oil drip rate correct
(approximately 1 drop for every 10 strokes)?
Are FRLs installed no more than 3 m from the
pneumatic equipment?
Are pressures adjusted to the correct value and
are operating ranges clearly indicated?

Pneumatic Equipment

Is any compressed air leaking from pneumatic

cylinders or solenoid valves?
Are all pneumatic cylinders and solenoid valves
firmly attached?
Are any makeshift fixings in use
(wire, adhesive tape, etc.)?
30

15

Pneumatic Checkpoints (Cont.)

Are any pistons dirty, worn, or damaged?
Are speed controllers installed the right way
around?
Is there any abnormal noise or overheating of
solenoid valves, and are any lead wires chafed or
trailing?
Piping and Wiring

Are there any places in pneumatic pipes or hoses

where fluid is liable to collect?
Are all pipes and hoses clipped firmly into place?
Are there any compressed-air leaks? are any
hoses cracked or damaged?
Are all valves operating correctly? Is it easy to see
whether valves are open or closed?
Are any pipes, wires, or valves unnecessary?
31

Electrical Checkpoints
Control Panels

Are the interiors of distribution boards,

switchboards, and control panels kept clean, tidy,
and well-organized by the application f the 5S
principles? Have any extraneous objects or
flammable materials been left inside?
Is the wiring inside control panels in good
condition? Are any wires coiled or trailing?
Are all ammeters and voltmeters operating
correctly and clearly marked?
Are any instruments or display lamps broken? Are
any bulbs faulty?
Are any switches broken? Do all switches work
correctly?
Are control panel doors in good condition? Do they
open and close easily?
Are there any unused holes? Are control panels
waterproof and dustproof?
32

16

Electrical Checkpoints (Cont.)

Electrical Equipment

Sensors

Are all motors free of overheating, vibration, and

unusual noise and smells?
Are all motor cooling fans and fins clean?
Are any attachment bolts loose? Are pedestals
free of cracks and other damage?
Are all limit switches clean and free of excessive
play?
Are the interiors of all limit switches clean? Are any
wires trailing? Are all covers in good condition?
Are any limit switches incorrectly installed?
Are any limit switch dogs worn, deformed, or the
wrong shape?
Are all photoelectric switches and proximity
switches clean and free of excessive play?
Are any sensors out of position? Are correct
positions clearly indicated?
Are all lead wires unchated, and is insulation intact
at entry points?
33

Electrical Checkpoints (Cont.)

Switches

Are all manual switches clean, undamaged, and

free of excessive play?
Are all switches installed in the correct position?
Are emergency stop switches installed in
appropriate locations, and are they working
correctly?

Piping and Wiring

Are any pipes, wires, or power leads looser or

unsecured?
Are any ground wires damaged or disconnected?
Are any pipes corroded o r damaged? Are there
any bare wires or wires with damaged insulation?
Are any wires coiled on the floor or dangling
overhead?

34

17

Checkpoints for General-Purpose Equipment

Pumps

Are pumps and their stands free of unusual noise, vibration, and
play?
Are pedestal bolts tight, corrosion-free, and undamaged?
Are stands and pedestals free of corrosion, cracking, and other
damage?
Is any liquid leaking or spraying from gland packings?
Is any liquid leaking or spraying from pipes or valves?
Are any pipes or valves blocked?
Are all pressure gauges, vacuum gauges, flowmeters, thermometers,
and other measuring instruments working property and marked with
the correct operating ranges?
Are starting current and operating current valves correct?
Are these clearly indicated?
Are all valves operating correctly? Is it easy to see whether whether
valves are open or closed?
35

Checkpoints for General-Purpose

Equipment (Cont.)
Fans

Are fans and their stands free of unusual noise, vibration, and play?
Are all pedestal bolts light, corrosion-free, and undamaged?
Are all stands and pedestals free of corrosion, cracking, and other
damaged?
Are any gland packings leaking air or gas?
Are any ducts or dampers leaking air or gas?
Are any ducts blocked or clogged?
Are all pressure gauges, vacuum gauges, flowmeters, thermometers,
and other measuring instruments working properly and marked with
the correct operating ranges?
Are starting current and operating current values correct?
Are these clearly indicated?
Are all dampers operating correctly? Is it easy to see whether
dampers are opened or closed?
36

18

ABNORMALITY TAGS

White Tags Removed by Line Operators

37

ABNORMALITY TAGS

Red Tags Removed by Skilled Person

38

19

Autonomous Maintenance
Seven Steps of Jishu-Hozen (AM)
Step - 0

Implement 1S, 2S

Step - 1

Initial Cleaning

Step - 2

Generation of Countermeasures

Step - 3

Preparation of Tentative Standards

Step - 4

General Inspection

Step - 5

Autonomous Inspection

Step - 6

Standardization

Step - 7

Autonomous Management
39

JH Step 0 - 1S, 2S
1S SEIRI - Sorting
Meaning :
Sorting necessary & unnecessary
things from your workplace.
Removing all unnecessary things.

Work to do :
Decide what is necessary & what is unnecessary
Separate the things in reworkable, repairable, reusable, in
excess.
Clearing some special places (like corners, below staircase)
which have lot of unnecessary things dumped.

Measure of Performance :
Neat workplace
Saving of place
40

20

JH Step 0 - 1S, 2S
2S SEITON - Systematic Arrangement
Meaning :
Place for Everything everything in its place
Management of keeping things
in proper place, quantity & manner.

Work to do :
Deciding the proper place for everything
Keeping things most used,
within arms reach
Following everything in its place.

Measure of Performance :
Saving in searching time.
Better workplace, Single touch pick-up
41

Single Touch Pickup -Shadow Boards

Before

After

42

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