Jishu Hozen

(Autonomous
Maintenance)
Presentation

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 Index
JH Concept JH master Plan
Why Fugai list
Breakdown Fugai Matrix
JH step-2
Needs of JH
Kaizens
JH targets CLIRt standards
JH steps Visualization of
Machine

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 JH- JISHU HOZEN
JH-AUTONOMOUS MAINTENANCE FOR
BREAKDOWN ELIMINATION

Even if
Preventive Maintenance
is Implemented thoroughly

then
Why Breakdown?
Because of
Forced and Natural
deterioration
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 JISHU-HOZEN

JISHU => AUTONOMOUS => SELF CONTROLLED

HOZEN => MAINTENANCE => SUSTENANCE

JH FOCUS ON

OPERATOR AND EQUIPMENT

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Forced Deterioration Happens Only If

1. Basic Conditions/ Requirements are

not Fulfilled
2. Basic Rules are not Followed

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 Why BREAKDOWN
Natural Deterioration
Planned Maintenance (PM,TBM,CBM)
Extend Life Time
Corrective Maintenance
Prevent breakdown by
improving TBM (time based maint)
Improve part life by doing
corrective maintenance &
Repair Quality
Improve safety & Reliability
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Forced Deterioration
Autonomous Maintenance
Eliminate Causes
Establish Basic Condition
Cleaning : Eliminate all dust &
Dirt
Lubricating : Keep lubricants
clean and replenished
Tightening : Keep bolts tight
Inspection: Required
parameters
6
 Need of JH

Inadequate
Machine
Knowledge I OPERATE,
Oil leakage YOU
from MC MAINTAIN
MINDSET

Spillage of Oil
High & Water
cleaning Why JH Around The
time Machine

Repetitive Un Safe
break down Condition

High Break
Down Time

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 JH target

Zero Break Down Due To Weak JH.

Zero Accident Due To Weak JH.

Zero Defect Due To Weak JH.

CLIRT Time Reduction.

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 JH Steps (Jishu-Hozen)

JH Steps
Step-0 Know your Equipment.
Step-1 Initial Cleaning and finding abnormalities.
Step-2 Counter measure against source of contamination
Step-3 Establish CLIRt tentative standards
Step-4 General inspection training
Step-5 Conduct General inspection autonomously
Step-6 Visual Maintenance Management
Step-7 Standardization and autonomous management.

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 Methodology/Activities in JH steps
JH Team (circle) formation and work allocation
1S, 2S, &3S around the machine
Step0 Collecting m/c past history breakdown ,defect & accident
Know your Equipment & know why sheet
Training to JH team on JH awareness, Know your Equipment & know w

Thoroughly Cleaning with inspection to identify abnormalities

Step1 Attached Red/White tags on machine to abnormalities
Preparation of FUGAI list & matrix
Removed all attached tags,
Identify the kaizen scope related to
-Source of contamination
-Hard to clean
Step2 -Hard to access
-Hard to inspect
Fabricate all identified Kaizens

Preparation of tentative CLIRt standards

Step3 Visualization of machine by text, sticker & symbols to make user frien
Make CLIRt route map

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 JH Step 0 (Know your Equipment)

Step 0 (Know your Equipment)

Understand the machine

parts/ assecceries and its
functions
Past breakdown, Defects and
accident history of machine.
7 Types of abnormality which
likely to be found
Understanding of RED and
WHITE Tags.
Safety instruction which to be
followed during cleaning i.e.
DO & DONT
Know equipment & Know why sheet

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 Abnormality tags

Red tag removed by maintenance

White tag removed by
person
production personnel
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 DOS AND DONTS DURING JH
Use PPEs (personal protective equipments) while working like
Hand gloves, Goggle, Helmet etc.
Do not used compressed air for cleaning
Locked the ladders, mobile platform before climbing
Switch off the electrical supply before opening electrical panels
Drain accumulator before removing hydraulic pipes
Shut off air supply valves
In case of doubt ask the maintenance person for safety
precautions

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 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,
looseness Belts, Chains

Abnormal Unusual noise, overheating, Vibration,

Phenomenon strange smells, discoloration, incorrect
pressure or current
Adhesion Blocking, hardening, accumulation of debris,
peeling, malfunction

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 2. UNFULFILLED BASIC CONDITIONS

Lubrication Insufficient, Dirty, Unidentified, unsuitable,

Leaking

Lubrication Dirty, damaged or deformed lubricant

Supply 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,
Unsuitable washers, wing nuts on
backward

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 3. IN-ACCESSIBLE PLACES

Cleaning Machine construction, Covers, Layout, footholds,

Space

Checking Construction, Covers, Layout, footholds,

Instrument position and Orientation, Operating
Range display

Lubricating Position of lubricant inlet, construction, height,

footholds, lubricant outlets, space

Tightening Covers, Construction, Layout size, Space

Operation Machine layout, Position of valves, Switches and

leavers, Footholds

Adjustment Position of pressure gauges, thermometers, flow

meters, moisture gauges, vacuum gauges, etc.

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 4. CONTAMINATION SOURCES

Product Leaks, Spills, Scattering, Overflow

Raw materials Leaks, Spills, Scattering, Overflow
Lubricants Leaking, Spills, Seeping oils, Hydraulic oil, etc.

Gases Leaking compressed air, gases, steam, vapors,

exhaust fumes, etc.

Liquids Leaking water, Hot, Cold, half finished products,

Waste water, Leaking supply lines etc.

Scrap Flashes, cuttings, packaging materials, and non

conforming products.

Others Contaminants by people & Forklifts, Infiltration

through cracked walls, broken windows etc.

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 5. QUALITY DEFECT SOURCES

Foreign Matter Dust, Rust, chips, moisture, paper pieces,

etc.

Moisture Too little or Too much, infiltration

Gain Size Abnormalities in screens, Compressed air
separators, centrifugal separators,

Concentration Inadequate warming, heating, compounding,

mixing, evaporation, stirring etc.

Viscosity Inadequate warming, heating, compounding,

mixing, evaporation, stirring etc.

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 6. UNNECESSARY AND NON-URGENT ITEMS

Machinery Pumps, fans, compressors, columns, tanks

etc.
Piping equipment Pipes, hoses, ducts, valves, dampers etc.
Measuring Temperatures, pressure gauges, vacuum
instruments gauges, ammeters etc.
Electrical Wiring, piping, power leads, switches, plugs
equipment etc.
Jigs & Tools General tools, cutting tools, jigs, molds,
dies, frames etc.
Spare parts Standby equipment, spares, permanent
stocks, auxiliary materials, etc.

Makeshift repairs Tape. String, wire, metal plates etc.

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 7. UNSAFE PLACES

Floors Unevenness, cracked, holes, .

Steps Too steep, irregular, slipping, missing handrails,
etc.
Lights Dim, out of position, dirty or broken covers, no
explosion proofing, etc.
Rotating Displaced, fallen oil or broken covers, not safe for
machinery emergency, missing emergency stop devices
Lifting Wires, hooks, brakes and other parts of cranes
Devices and hoists etc.

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 Kaizen Hard To Inspect

BEFORE AFTER

Difficult to inspect the air Green and Red sticker pasted on

pressure in the machine gauge for easy visual

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 Kaizen Hard To Inspect

BEFORE AFTER

Difficult to inspect oil level Green and Red sticker pasted

on level glass on the level glass for easy
visual

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 Kaizen Hard To Inspect

BEFORE AFTER

Difficult to inspect hanger load qty in Hanger load display made in such a way
control Panel that it is visual from all side

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 Kaizen Hard To Inspect

BEFORE AFTER

No Match-marking in bolts for Match-marking in All bolts by

easy inspection paint

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 Kaizen Hard To Inspect
Machine :- IM- 37 JSW(850T)

BEFORE AFTER

There was no pressure gauge to check Provide pressure gauge for checking
the contract pressure and system system &and contract pressure
pressure

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 Kaizen Hard To Clean
Machine :- IM-37 JSW(850T)

BEFORE AFTER

Rear safety gate was not fully open, so Now rear safety gate opening limit
it was hard to clean machine inside increase, so easy to clean inside
machine

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 Visualization of Machines

Visual and Visual Controls for 1. Examples

2. Working Range marking on
Inspection of Machine parts Pressure Gauges
3. Display of Working Range on
Operating parameters Digital Gauges
Operating Conditions 4. Direction mark of Motors
5. Color Coding
Procedures and Standards 6. Indicator lamps with label
7. alarm
Placement of Tools, gauges 8. Filter Conditions
and material 9. Working range on Oil Level
Indicators
Etc. 10. Mirror
11. Shadow/image
12. Match mark
13. Direction Mark
14. Transparent Guard
15. Coloring
16. Magnification/Projection
17. Floating
18. Etc.

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 Visualization of Machine
Overall Machine Visualization
Machine
Visualization
DIRECTION OF FLOW

CLIRt sheet point No:-

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