"" Exploremyself - Colours of Life: 2009 "

Tuesday, December 29, 2009

7. Unsafe places

Floors - Uneveness, cracked, projections, peeling etc.

Steps - Too steep, irregular, missing handrails, slippery.

Lights - Out of position, dirty or broken covers, dimensions.

Rotating machinery - Fallen or Broken covers, not safe, missing emergency Stop devices

Lifting Devices - Brakes and Parts of cranes and hoists, wires, hooks.

Others - Danger signs, insulating materials, special solvents,toxic gases,protective clothing etc.

Useful Links to Read:
01. history-of-total-productive-maintenance.html
02. why-implement-total-productive.html
03. what-is-tpm.html
04. 12-steps-for-tpm-implementation.html
05. typical-tpm-organizational-chart.html
06. effectiveness-of-tpm.html
07. 5-principles-in-tpm-development.html
08. purpose-and-main-activities-of-kk.html
09. purpose-and-activities-of-jh-pillar.html
10. purpose-activity-of-pm-pillar.html
11. purpose-activities-of-qm-pillar.html
12. purpose-and-activity-of-dm-pillar.html
13. purpose-and-activity-of-otpm-pillar.html
14. purpose-and-activity-of-e-pillar.html
15. purpose-and-activity-of-she-pillar.html
16. company-wide-tpm.html
17. jishu-hozen-information.html
18. ishu-hozen-equipment-deterioration.html
19. role-of-production-maintenance-in-jh.html
20. jishu-hozen-step-1.html
21. 1s-2s-implementation.html
22. jh-step-01-abnormalities.html
23. exposing-seven-types-of-abnormality.html
24. 2-unfulfilled-basic-condition.html
25. 3inaccessible-places.html.
26. 4-contamination-sources.html.
27. 5-quality-defect-sources.html.
28. 6-unnecessary-non-urgent-items.html.

6. Unnecessary & non urgent Items

Machinery - Pumps, fans, tanks, compressors.

Piping Equipment - Pipes, hoses, ducts, valves, dampers etc.

Measuring instruments - Pressure Gauges, Ammeters, Vaccum Gauges etc.

Electrical equipment - Wires, switches, plugs, power leads, piping.

Jigs & Tools - General tools, Jigs/Fixtures, cutting tools, dies.

Spare parts - Standby equipment, spares, auxiliary material.

Makeshift repairs - Tape, string, wire, metal plates

Useful Links to Read:
01. history-of-total-productive-maintenance.html
02. why-implement-total-productive.html
03. what-is-tpm.html
04. 12-steps-for-tpm-implementation.html
05. typical-tpm-organizational-chart.html
06. effectiveness-of-tpm.html
07. 5-principles-in-tpm-development.html
08. purpose-and-main-activities-of-kk.html
09. purpose-and-activities-of-jh-pillar.html
10. purpose-activity-of-pm-pillar.html
11. purpose-activities-of-qm-pillar.html
12. purpose-and-activity-of-dm-pillar.html
13. purpose-and-activity-of-otpm-pillar.html
14. purpose-and-activity-of-e-pillar.html
15. purpose-and-activity-of-she-pillar.html
16. company-wide-tpm.html
17. jishu-hozen-information.html
18. ishu-hozen-equipment-deterioration.html
19. role-of-production-maintenance-in-jh.html
20. jishu-hozen-step-1.html
21. 1s-2s-implementation.html
22. jh-step-01-abnormalities.html
23. exposing-seven-types-of-abnormality.html
24. 2-unfulfilled-basic-condition.html
25. 3inaccessible-places.html.
26. 4-contamination-sources.html.
27. 5-quality-defect-sources.html.

5. Quality Defect Sources

Foreign matter - Chips, wire scraps, rust, insects, infiltration, dust.

Shock - Vibration, collision, droppings

Moisture - Too little or too much, infiltration

Concentration - Inadequate warming up, heating, compounding, Mixing, evaporation, stirring etc.

Viscosity - Inadequate warming up, heating, compounding,Mixing, evaporation, stirring.

Useful Links to Read:
01. history-of-total-productive-maintenance.html
02. why-implement-total-productive.html
03. what-is-tpm.html
04. 12-steps-for-tpm-implementation.html
05. typical-tpm-organizational-chart.html
06. effectiveness-of-tpm.html
07. 5-principles-in-tpm-development.html
08. purpose-and-main-activities-of-kk.html
09. purpose-and-activities-of-jh-pillar.html
10. purpose-activity-of-pm-pillar.html
11. purpose-activities-of-qm-pillar.html
12. purpose-and-activity-of-dm-pillar.html
13. purpose-and-activity-of-otpm-pillar.html
14. purpose-and-activity-of-e-pillar.html
15. purpose-and-activity-of-she-pillar.html
16. company-wide-tpm.html
17. jishu-hozen-information.html
18. ishu-hozen-equipment-deterioration.html
19. role-of-production-maintenance-in-jh.html
20. jishu-hozen-step-1.html
21. 1s-2s-implementation.html
22. jh-step-01-abnormalities.html
23. exposing-seven-types-of-abnormality.html
24. 2-unfulfilled-basic-condition.html
25. 3inaccessible-places.html.html
26. 4-contamination-sources.html.html

4. Contamination Sources

Product - Scattering , overflow, leaks, spills.

Raw material - Scattering , overflow, leaks, spills.

Lubricants - Leaking, Spills, seeping oils, hydraulic fluids etc.

Gases - Leaking compressed air, gases, steam, exhaust fumes

Scrap - Cuttings, packaging material, non-confirming products.

Others - Contaminants brought in by people, forklift trucks, material handling equipments etc.

Useful Links to Read:
01. history-of-total-productive-maintenance.html
02. why-implement-total-productive.html
03. what-is-tpm.html
04. 12-steps-for-tpm-implementation.html
05. typical-tpm-organizational-chart.html
06. effectiveness-of-tpm.html
07. 5-principles-in-tpm-development.html
08. purpose-and-main-activities-of-kk.html
09. purpose-and-activities-of-jh-pillar.html
10. purpose-activity-of-pm-pillar.html
11. purpose-activities-of-qm-pillar.html
12. purpose-and-activity-of-dm-pillar.html
13. purpose-and-activity-of-otpm-pillar.html
14. purpose-and-activity-of-e-pillar.html
15. purpose-and-activity-of-she-pillar.html
16. company-wide-tpm.html
17. jishu-hozen-information.html
18. ishu-hozen-equipment-deterioration.html
19. role-of-production-maintenance-in-jh.html
20. jishu-hozen-step-1.html
21. 1s-2s-implementation.html
22. jh-step-01-abnormalities.html
23. exposing-seven-types-of-abnormality.html
24. 2-unfulfilled-basic-condition.html
25. 3inaccessible-places.html.html

3.Inaccessible Places

Cleaning - Covers, layout, machine construction, footholds, space

Checking - Instrument position and orientation,operating range display, covers, construction, layout.

Lubricating - Position of lubricant inlet, height space.

Tightening - Covers, construction, layout, size, space.

Operation - Machine layout, position of switches, levers and valves.

Adjustment - Position of pressure gauges, flow meters, thermometers, vaccum gauges etc.

Useful Links to Read:
01. history-of-total-productive-maintenance.html
02. why-implement-total-productive.html
03. what-is-tpm.html
04. 12-steps-for-tpm-implementation.html
05. typical-tpm-organizational-chart.html
06. effectiveness-of-tpm.html
07. 5-principles-in-tpm-development.html
08. purpose-and-main-activities-of-kk.html
09. purpose-and-activities-of-jh-pillar.html
10. purpose-activity-of-pm-pillar.html
11. purpose-activities-of-qm-pillar.html
12. purpose-and-activity-of-dm-pillar.html
13. purpose-and-activity-of-otpm-pillar.html
14. purpose-and-activity-of-e-pillar.html
15. purpose-and-activity-of-she-pillar.html
16. company-wide-tpm.html
17. jishu-hozen-information.html
18. ishu-hozen-equipment-deterioration.html
19. role-of-production-maintenance-in-jh.html
20. jishu-hozen-step-1.html
21. 1s-2s-implementation.html
22. jh-step-01-abnormalities.html
23. exposing-seven-types-of-abnormality.html
24. 2-unfulfilled-basic-condition.html

2. Unfulfilled Basic Condition

Lubrication - Insufficient, dirty, unidentified, unsuitable,leaking lubricant.

Lubricant supply - Dirty, damaged, deformed lubricant inlets,faulty lubricant pipes.

Oil level gauges - Dirty, damaged, leaking, no indication of correct level.

Tightening - Nuts & bolts loose, slackness, missing, crushed,cross hreaded,corroded, washers missing, Unsuitable washers, wing nuts on back side


Useful Links to Read:
01. history-of-total-productive-maintenance.html
02. why-implement-total-productive.html
03. what-is-tpm.html
04. 12-steps-for-tpm-implementation.html
05. typical-tpm-organizational-chart.html
06. effectiveness-of-tpm.html
07. 5-principles-in-tpm-development.html
08. purpose-and-main-activities-of-kk.html
09. purpose-and-activities-of-jh-pillar.html
10. purpose-activity-of-pm-pillar.html
11. purpose-activities-of-qm-pillar.html
12. purpose-and-activity-of-dm-pillar.html
13. purpose-and-activity-of-otpm-pillar.html
14. purpose-and-activity-of-e-pillar.html
15. purpose-and-activity-of-she-pillar.html
16. company-wide-tpm.html
17. jishu-hozen-information.html
18. ishu-hozen-equipment-deterioration.html
19. role-of-production-maintenance-in-jh.html
20. jishu-hozen-step-1.html
21. 1s-2s-implementation.html
22. jh-step-01-abnormalities.html
23. exposing-seven-types-of-abnormality.html

Monday, December 28, 2009

Exposing Seven types of Abnormality

7 Types Of Abnormalities:- 1. Minor Flaws

Contamination - Dust, dirt, oil, grease, rust, paint.

Damage - Cracking, crushing, deformation, chipping, bending.

Play - Shaking, falling out, tilting, eccentricity, wear, distortion,corrosion.

Slackness - Belts, chains.

Abnormal phenomenon - Unusual noise, overheating, vibration, strange smell, discolouration, incorrect pressure or current.

Adhesion - Blocking, hardening, accumulation of debris, peeling,malfunction.


Useful Links to Read:
01. history-of-total-productive-maintenance.html
02. why-implement-total-productive.html
03. what-is-tpm.html
04. 12-steps-for-tpm-implementation.html
05. typical-tpm-organizational-chart.html
06. effectiveness-of-tpm.html
07. 5-principles-in-tpm-development.html
08. purpose-and-main-activities-of-kk.html
09. purpose-and-activities-of-jh-pillar.html
10. purpose-activity-of-pm-pillar.html
11. purpose-activities-of-qm-pillar.html
12. purpose-and-activity-of-dm-pillar.html
13. purpose-and-activity-of-otpm-pillar.html
14. purpose-and-activity-of-e-pillar.html
15. purpose-and-activity-of-she-pillar.html
16. company-wide-tpm.html
17. jishu-hozen-information.html
18. ishu-hozen-equipment-deterioration.html
19. role-of-production-maintenance-in-jh.html
20. jishu-hozen-step-1.html
21. 1s-2s-implementation.html
22. jh-step-01-abnormalities.html

JH Step-01 Abnormalities

Abnormalities ..

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

Example of Abnormalities

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

Seven types of Abnormalities

1. Minor Flaws

2 Unfulfilled Basic Conditions
3 Inaccessible Places

4 Contamination Sources
5 Quality Defect Sources
6 Unnecessary and Non-urgent items

7 Unsafe Places


Useful Links to Read:
01. history-of-total-productive-maintenance.html
02. why-implement-total-productive.html
03. what-is-tpm.html
04. 12-steps-for-tpm-implementation.html
05. typical-tpm-organizational-chart.html
06. effectiveness-of-tpm.html
07. 5-principles-in-tpm-development.html
08. purpose-and-main-activities-of-kk.html
09. purpose-and-activities-of-jh-pillar.html
10. purpose-activity-of-pm-pillar.html
11. purpose-activities-of-qm-pillar.html
12. purpose-and-activity-of-dm-pillar.html
13. purpose-and-activity-of-otpm-pillar.html
14. purpose-and-activity-of-e-pillar.html
15. purpose-and-activity-of-she-pillar.html
16. company-wide-tpm.html
17. jishu-hozen-information.html
18. ishu-hozen-equipment-deterioration.html
19. role-of-production-maintenance-in-jh.html
20. jishu-hozen-step-1.html
21. 1s-2s-implementation.html

1S-2S Implementation

1 Seiri – Sort –Eliminating unnecessary items from the work place.
An effective visual method to identify these unwanted items. A red tag is placed on all items. These are then moved to a new area. This is for evaluation of red tag. But , to be decided with in a time period.

2 . Set in order – Seiton – Efficient & Effective storage method.
Strategies for effective or outlining work areas and locations, shadow board and modular shelving and cabinets for needed items.

1S 2S Implementation Methodology

1) Division of factory premises into various zones (zone limit to single digit)

2) Formation of team (Leader & members)

3) Master plan for 1S 2S company wide

4) Master plan for 1S 2S activity for each zone

5) Background of zone ( If you want to start the bad condition you can start )

6) 1S implementation : Required items Not Required items ( one time activity )
Move to Red tag Area

7) Action plan for parts in red tag area.

8) Before & after photo with key points at the bottom(Fixed point photo)

9) Self Audit

10) Other zone leaders audit with improvements points

11) 2S implementation : Required quantity to define , assigning a place , marking / labeling ,Based on place you have allocated Keeping parts / accessories in the allocated place.(Need to get feedback from work force)

12) Self audit.

13) Other zonal leader audit.

14) By 1S 2S : improvements achieved – system related & Layout related

15) Benefits got out from 1S 2S zone wise


Useful Links to Read:
01. history-of-total-productive-maintenance.html
02. why-implement-total-productive.html
03. what-is-tpm.html
04. 12-steps-for-tpm-implementation.html
05. typical-tpm-organizational-chart.html
06. effectiveness-of-tpm.html
07. 5-principles-in-tpm-development.html
08. purpose-and-main-activities-of-kk.html
09. purpose-and-activities-of-jh-pillar.html
10. purpose-activity-of-pm-pillar.html
11. purpose-activities-of-qm-pillar.html
12. purpose-and-activity-of-dm-pillar.html
13. purpose-and-activity-of-otpm-pillar.html
14. purpose-and-activity-of-e-pillar.html
15. purpose-and-activity-of-she-pillar.html
16. company-wide-tpm.html
17. jishu-hozen-information.html
18. ishu-hozen-equipment-deterioration.html
19. role-of-production-maintenance-in-jh.html
20. jishu-hozen-step-1.html

Jishu Hozen - Step 1



AIM


The Equipment


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


Personnel:


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


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


While cleaning, we have to inspect


What to Inspect?


Inspect ABNORMALITIES


Abnormalities ..


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



Useful Links to Read:
01. history-of-total-productive-maintenance.html
02. why-implement-total-productive.html
03. what-is-tpm.html
04. 12-steps-for-tpm-implementation.html
05. typical-tpm-organizational-chart.html
06. effectiveness-of-tpm.html
07. 5-principles-in-tpm-development.html
08. purpose-and-main-activities-of-kk.html
09. purpose-and-activities-of-jh-pillar.html
10. purpose-activity-of-pm-pillar.html
11. purpose-activities-of-qm-pillar.html
12. purpose-and-activity-of-dm-pillar.html
13. purpose-and-activity-of-otpm-pillar.html
14. purpose-and-activity-of-e-pillar.html
15. purpose-and-activity-of-she-pillar.html
16. company-wide-tpm.html
17. jishu-hozen-information.html
18. ishu-hozen-equipment-deterioration.html
19. role-of-production-maintenance-in-jh.html

Role Of Production & Maintenance In JH

ROLE OF PRODUCTION.

Play vital in A also records maintenance data for prevention of recurrences of problem & MP design.
Play role in B by five senses.
Play role in C by prompt reporting & assisting in sporadic failure.

ROLE OF MAINTENANCE.

Play role in as a guide & educationist & providing help in identifying areas source of problems & hard to clean.
Play in role B by vibration & fluid analysis.
Play major role in C by improving MTBF, MTTR.
Besides that they maintain MIS ,work for new equipment design & set up maintenance standards


How do we do it ? Step by Step !

Autonomous Maintenance is the foundation stone of TPM. Without operators who can look after their own machines, losses and break-downs cannot be reduced.

As people become more confident, there is a vital change in attitude


Useful Links to Read:
01. history-of-total-productive-maintenance.html
02. why-implement-total-productive.html
03. what-is-tpm.html
04. 12-steps-for-tpm-implementation.html
05. typical-tpm-organizational-chart.html
06. effectiveness-of-tpm.html
07. 5-principles-in-tpm-development.html
08. purpose-and-main-activities-of-kk.html
09. purpose-and-activities-of-jh-pillar.html
10. purpose-activity-of-pm-pillar.html
11. purpose-activities-of-qm-pillar.html
12. purpose-and-activity-of-dm-pillar.html
13. purpose-and-activity-of-otpm-pillar.html
14. purpose-and-activity-of-e-pillar.html
15. purpose-and-activity-of-she-pillar.html
16. company-wide-tpm.html
17. jishu-hozen-information.html
18. ishu-hozen-equipment-deterioration.html

Jishu Hozen - Equipment Deterioration

NATURAL DETERIORATION (Extend life time)

Corrective Maintenance

Prevent errors by improving operability.

Improve maintainability & Repair quality

Improve safety & Reliability.


FORCED DETERIORATION (Eliminate causes)

Establish basic condition

Cleaning: eliminate all dust & dirt.

Lubricating: Keep lubricants clean & replenished.

Tightening :Keep nuts & bolts secure.

Classification of Maintenance activities

A ) Activities to prevent deterioration By correct operation ,improvement of basic conditions & adjustments to prevent quality defects.

B) Activities to measure deterioration By senses ( touch,see,hear, smell)

C) Activities to rectify deterioration By improving reliability & maintainability of machines ( MTBF,MTTR)



Useful Links to Read:
01. history-of-total-productive-maintenance.html
02. why-implement-total-productive.html
03. what-is-tpm.html
04. 12-steps-for-tpm-implementation.html
05. typical-tpm-organizational-chart.html
06. effectiveness-of-tpm.html
07. 5-principles-in-tpm-development.html
08. purpose-and-main-activities-of-kk.html
09. purpose-and-activities-of-jh-pillar.html
10. purpose-activity-of-pm-pillar.html
11. purpose-activities-of-qm-pillar.html
12. purpose-and-activity-of-dm-pillar.html
13. purpose-and-activity-of-otpm-pillar.html
14. purpose-and-activity-of-e-pillar.html
15. purpose-and-activity-of-she-pillar.html
16. company-wide-tpm.html
17. jishu-hozen-information.html

Jishu Hozen Information

Dear Friends Let us see one by one Pillar Implementation here. We are starting from JH Pillar First.

BASIC CONCEPT

If all personnel who are engaged in the equipment operation can change their basic concept and behavior, the stoppage or deterioration of equipment functions could be prevented and “Zero Failures and Defects” could be achieved.

If equipment is changed, the workers will change.If the workers change, the production field can be changed Self fulfillment should be realized through employment of a step-by-step
system to positively promote the development,with all workers participating in the activities under the organization led small groups.

DEFINITION

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

THE CHANGE THROUGH JH PRACTICE

I RUN IT, YOU FIX IT

To Becomes

I RUN IT, I FIX IT


Useful Links to Read:
01. history-of-total-productive-maintenance.html
02. why-implement-total-productive.html
03. what-is-tpm.html
04. 12-steps-for-tpm-implementation.html
05. typical-tpm-organizational-chart.html
06. effectiveness-of-tpm.html
07. 5-principles-in-tpm-development.html
08. purpose-and-main-activities-of-kk.html
09. purpose-and-activities-of-jh-pillar.html
10. purpose-activity-of-pm-pillar.html
11. purpose-activities-of-qm-pillar.html
12. purpose-and-activity-of-dm-pillar.html
13. purpose-and-activity-of-otpm-pillar.html
14. purpose-and-activity-of-e-pillar.html
15. purpose-and-activity-of-she-pillar.html
16. company-wide-tpm.html

Thursday, December 24, 2009

Company wide TPM

1. TPM aims to create a corporate system that maximizes the efficiency of the production system (overall efficiency improvement)

2. TPM creates systems for preventing the occurrence of all losses on the front line and is focused on the end product. This includes systems for realizing "zero accidents, zero defects, and zero failures" in the entire life cycle of the production system

3. TPM is applied in all sectors, including the production, development, and administration departments.

4. TPM is based on the participation of all members, ranging from the top management to frontline employees.

5. TPM achieves zero losses through overlapping small-group activities. Get your dog a sombrero


Useful Links to Read:
01. history-of-total-productive-maintenance.html
02. why-implement-total-productive.html
03. what-is-tpm.html
04. 12-steps-for-tpm-implementation.html
05. typical-tpm-organizational-chart.html
06. effectiveness-of-tpm.html
07. 5-principles-in-tpm-development.html
08. purpose-and-main-activities-of-kk.html
09. purpose-and-activities-of-jh-pillar.html
10. purpose-activity-of-pm-pillar.html
11. purpose-activities-of-qm-pillar.html
12. purpose-and-activity-of-dm-pillar.html
13. purpose-and-activity-of-otpm-pillar.html
14. purpose-and-activity-of-e-pillar.html
15. purpose-and-activity-of-she-pillar.html

Purpose and Activity of SHE Pillar

Safety Health & Environment

Purpose:

Achievement and support of zero failures
Realization of a healthy and invigorating workplace that gives meaning to work

Members:

Safety, health and environment managers and specialised committee members
Staff specialising in safety and health

Activities:

Measures to improve equipment safety
Measures to improve work safety
Improvement of work environment (noise, vibration and odors)
Measures to prevent pollution
Creation of healthy employees
Promotion of invigorating activities


Useful Links to Read:
01. history-of-total-productive-maintenance.html
02. why-implement-total-productive.html
03. what-is-tpm.html
04. 12-steps-for-tpm-implementation.html
05. typical-tpm-organizational-chart.html
06. effectiveness-of-tpm.html
07. 5-principles-in-tpm-development.html
08. purpose-and-main-activities-of-kk.html
09. purpose-and-activities-of-jh-pillar.html
10. purpose-activity-of-pm-pillar.html
11. purpose-activities-of-qm-pillar.html
12. purpose-and-activity-of-dm-pillar.html
13. purpose-and-activity-of-otpm-pillar.html
14. purpose-and-activity-of-e-pillar.html

Purpose and activity of E&T Pillar

Education & Training Pillar

Purpose:

Establishment of technical education for operations and maintenance workers

Members:

Operators
Maintenance workers


Activities:

Basic process of maintenance
Tightening nuts and bolts
Aligning keys
Maintenance of bearings
Maintenance of conductive parts
Prevention of leaks
Maintenance of oil pressure and air pressure equipment
Maintenance of electrical control equipment


Useful Links to Read:
01. history-of-total-productive-maintenance.html
02. why-implement-total-productive.html
03. what-is-tpm.html
04. 12-steps-for-tpm-implementation.html
05. typical-tpm-organizational-chart.html
06. effectiveness-of-tpm.html
07. 5-principles-in-tpm-development.html
08. purpose-and-main-activities-of-kk.html
09. purpose-and-activities-of-jh-pillar.html
10. purpose-activity-of-pm-pillar.html
11. purpose-activities-of-qm-pillar.html
12. purpose-and-activity-of-dm-pillar.html
13. purpose-and-activity-of-otpm-pillar.html
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