PILLAR

Jishu Hozen

or

Autonomous Maintenance

TPM Club India Page JH - 1  Confederation of Indian Industry

 Reasons Why Autonomous Maintenance is Required
No satisfactory increase in the
performance record can be seen … Activities to keep
record on equipment
• Confirmation of degradation
working conditions
• Daily inspection
• Periodical inspection

Activities to prevent
equipment degradation

• Keep cleaning
• Inspection
• Additional
tightening

Activities to restore
Preventive Production the machine
Maintenance Maintenance TPM conditions

U.S style of PM Japanese

style of PM
Maintenance
Department’s
sole • Frequent servicing
responsibility
• Solution of abnormality
• Good communication

TPM Club India Page JH - 2  Confederation of Indian Industry

 Why Jishu Hozen

• To prevent equipment deterioration

• To maintain equipment in optimal condition
• To establish basic equipment condition
• To eliminate equipment failure
• To make operator familiar with his equipment
• To eliminate Quality defect
• To eliminate cost losses

TPM Club India Page JH - 3  Confederation of Indian Industry

 The Mind set ………..
Individual preserving one’s own equipment
Significant change from early theory of
“ I manufacture – You repair”
or
“I make - You Fix”

PRODUCTION MAINTENANCE
• Maintenance does not its job • Production do not know how to
• They take too long to fix the equipment operate
• This equipment is so old no wonder it • We get lot of repairs so we don’t
breaks down again and again have time to do a real corrective
action and are forced to do only
• We are too busy to do vital daily checks temporary job
• We prepare the standards but they
do not do the checks
TPM Club India Page JH - 4  Confederation of Indian Industry
 Equipment Deterioration

Natural Deterioration Accelerated Deterioration

Extend Life Time Eliminate Causes

Corrective Maintenance Establish Basic Condition

• Prevent errors by improving • Cleaning : Eliminate all
operability dust & Dirt
• Improve Maintainability & • Lubricating : Keep
Repair Quality lubricants clean and
• Improve safety & Reliability replenished
• Tightening : Keep nuts &
bolts secure
TPM Club India Page JH - 5  Confederation of Indian Industry
 Classification of Maintenance Activities
A. Activities to prevent deterioration
By correct operation, Improvement of basic conditions and 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)
ROLE OF PRODUCTION ROLE OF MAINTENANCE
• Play vital role in A. also records • Play role in as a guide and educationist and
maintenance data for prevention providing help in identifying areas “sources of
of recurrences of problem and MP problems and “ Hard to Clean”
design. • Play in role B by vibration and fluid Analysis.
• Play role in B by five senses • Play major role in C by improving MTBF, MTTR.
• Play role in C by prompt reporting • Besides that they maintain MIS, work for new
and assisting in sporadic failure equipment design and set up maintenance
standards
TPM Club India Page JH - 6  Confederation of Indian Industry
 7 Steps for Evolving Autonomous Maintenance
Step Name
1 Initial clean-up All-around clean-up of dust and dirt, centering on equipment proper, and
implementation of lubrication, and machine parts adjustment; discovery and
repair of malfunctions in equipment
2 Measures against Sources Prevent causes of dust and dirt and scattering, improve places which are difficult
to clean and lubricate and reduce the time required for clean-up and lubrication.

3 Formulation of clean-up and Formulate behavioral standards so that it is possible to steadily sustain clean-up,
lubrication standards lubrication and machine parts adjustment in a short period (Necessary to indicate
a time frame-work that can be used daily or periodically)….

4 Overall inspection Training in check-up skills through check-up manuals; exposure and restoration of
minor equipment defects through overall check-ups

5 Autonomous check-up Formulation and implementation of autonomous check-up sheets

6 Orderliness and tidiness Standardize various types of on-the job management items and devise complete
systematization of up-keep management.
• Standards for clean-up, check-ups and lubrication
• Standards for physical distribution in the workplace
• Standardization of data records
• Standardization of die management, jigs and tools
7 All-out autonomous Development of corporate policies and goals, and making improvement activities
management routine : Steadily record MTBF analysis, analyze these, and carry out equipment
improvements
TPM Club India Page JH - 7  Confederation of Indian Industry
 Step 0

Initial Preparation

TPM Club India Page JH - 8  Confederation of Indian Industry

 Preparations for JH Activities

• Prepare a Cleaning & Lubrication map

• Arrange Tools
• Arrange Red & White Tags
• History of Failures
• Training on 7 steps of Jishu Hozen
• Training on 7 types of abnormalities

TPM Club India Page JH - 9  Confederation of Indian Industry

 Step 1

Initial Cleaning

TPM Club India Page JH - 10  Confederation of Indian Industry

 STEP 1 : Initial Clean up

• CLEANING IS INSPECTION

• USE 5 SENSES FOR CLEANING

• FIND OUT 7 TYPE OF ABNORMALITIES

• PUT TAGS ON ABNORMALITIES

• PREPARE LIST OF UNFULFILLED BASIC

CONDITIONS

TPM Club India Page JH - 11  Confederation of Indian Industry

 STEP 1 : Initial Clean up

Make the list of

• Hard to clean,
• hard to lubricate,
Areas / Parts
• hard to tighten,
• hard to inspect,
• hard to adjust
• Record cleaning time
• Carry out audit on 1st step
• Meeting after the daily activities
• Refer to the old history records
TPM Club India Page JH - 12  Confederation of Indian Industry
 7 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

TPM Club India Page JH - 13  Confederation of Indian Industry

 1- Minor Flaws
Contamination Dust, Dirt, powder, oil, grease, rust, paint
Cracking, crushing, deformation, chipping,
Damage bending,

Shaking, falling out, tilting, eccentricity, wear,

Play distortion, corrosion,

Belts, Chains
Slackness

Abnormal Unusual noise, overheating, Vibration, strange

Phenomenon smells, discoloration, incorrect pressure or current

Blocking, hardening, accumulation of debris,

Adhesion peeling, malfunction
TPM Club India Page JH - 14  Confederation of Indian Industry
 2 - Unfulfilled Basic Conditions

Insufficient, Dirty, Unidentified, unsuitable,

Lubrication
Leaking
Lubrication Dirty, damaged or deformed lubricant inlets,
Supply faulty lubricant pipes
Dirty, Damaged, leaking, No indication of
Oil level gauges
correct level
Nuts and Bolts slackness, Missing, Cross-
Tightening threaded, Too long, Crushed, Corroded,
Unsuitable washers, wing nuts on backward

TPM Club India Page JH - 15  Confederation of Indian Industry

 3 - Inaccessible Places
Machine construction, Covers, Layout, footholds,
Cleaning Space
Construction, Covers, Layout, footholds, Instrument
Checking position and Orientation, Operating – Range display

Position of lubricant inlet, construction, height,

Lubricating footholds, lubricant outlets, space

Tightening Covers, Construction, Layout size, Space

Machine layout, Position of valves, Switches and
Operation leavers, Footholds
Position of pressure gauges, thermometers, flow
Adjustment meters, moisture gauges, vacuum gauges, etc.
TPM Club India Page JH - 16  Confederation of Indian Industry
 4 – Contamination Sources
Product Leaks, Spills, Spurts, Scattering, Overflow
Raw materials Leaks, Spills, Spurts, Scattering, Overflow
Leaking, Spills, Seeping oils, Hydraulic fluids, Fuel
Lubricants oils, etc.
Leaking compressed air, gases, steam, vapors,
Gases exhaust fumes, etc.
Leaking water, Hot, Cold, half finished products,
Liquids Waste water, Leaking supply lines etc.
Flashes, cuttings, packaging materials, and non
Scrap conforming products.
Contaminants by people & Forklifts, Infiltration
Others through cracked walls, broken windows etc.
TPM Club India Page JH - 17  Confederation of Indian Industry
 5 – Quality Defect Sources
Dust, Rust, powder, chips, moisture, wire scraps,
Foreign Matter wood pieces, paper pieces, stones etc.

Shock Dropping, Jolting, collision, Vibration etc.

Moisture Too little or Too much, infiltration

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

Inadequate warming, heating, compounding,

Concentration mixing, evaporation, stirring etc.

Inadequate warming, heating, compounding,

Viscosity mixing, evaporation, stirring etc.
TPM Club India Page JH - 18  Confederation of Indian Industry
 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 etc.

equipment
General tools, cutting tools, jigs, molds, dies,
Jigs & Tools frames etc.
Standby equipment, spares, permanent stocks,
Spare parts auxiliary materials, etc.

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

TPM Club India Page JH - 19  Confederation of Indian Industry
 7. Unsafe Places
Unevenness, cracked, holes, projections, peeling, wear
Floors of steel chucker plates, slipping.

Steps Too steep, irregular, slipping, missing handrails, etc.

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

Devices hoists etc.

Special substances, solvents, toxic gases, insulating

Others materials, danger signs, protective clothing etc.
TPM Club India Page JH - 20  Confederation of Indian Industry
 Harmful Effects of Inadequate Cleaning
Dirt and foreign matter penetrates rotating parts, sliding
parts, pneumatic and hydraulic systems, electrical control
Failure systems and sensors etc., causing loss of precision,
malfunction and failure as a result of wear, blockage,
frictional resistance, electrical faults etc.

Quality Defects are caused either directly by

Quality contamination of the product with foreign matter or
Defects indirectly as a result of equipment malfunction.

Accumulated dust and grime make it difficult to find and

Accelerated rectify cracks, excessive play, insufficient lubricants, and
Deterioration other disorders, resulting in accelerated deterioration.

Dust and dirt increase wear and frictional resistance

Speed Losses causing speed losses such as idling and under
performance.
TPM Club India Page JH - 21  Confederation of Indian Industry
 Points to be checked during

initial cleaning ( Sample)

TPM Club India Page JH - 22  Confederation of Indian Industry

 Checkpoints for Nuts & Bolts
Slight Loose nuts & bolts, missing nuts & bolts
defects
Bolt length All bolts should protrude from nuts by 2-3 threads
• Are flat washers used on long holes
• Are tapered washers used on angle bars & channels
Washers • Are spring washers used for parts subjected to
vibration
• Are identical washers used in identical parts
• Are bolts inserted from below, are they visible from
outside
Fixing of
• Are devices such as limit switches fastened at least
nuts & bolts
by 2 bolts
• Are wing nut direction clock wise
TPM Club India Page JH - 23  Confederation of Indian Industry
 Lubrication checkpoints
• Are lubricant sores always kept clean, tidy, are 5S principles applied
Lubricant • Are lubricant containers always capped
storage • Are lubricant type clearly indicated and is proper stock control
practiced
• Are grease nipples, speed reducer lubricant ports and other lubricant
Lubricant inlets always kept clean
inlets • Are lubricant inlets dust proofed
• Are lubricant inlets labeled with correct type and quantity of lub.
• Are oil level gauges always kept clean, are oil levels easy to check
Oil level • Is the correct oil level clearly marked
gauges
• Is equipment free of oil leaks, and oil pipes& breathers unobstructed
Auto Lub • Are Auto lubricating devices operating correctly & supplying correct
Devices quantity of lubricants
Lubricating • Are rotating, sliding parts, and transmission well lubricated
condition • Are the surroundings free of contamination by excess lubricant
TPM Club India Page JH - 24  Confederation of Indian Industry
 Transmission System checkpoints
• Are any belt cracked, swollen, worn out, or contaminate by lub.
• Are any belts twisted or missing. Are any belts stretched or slack
V-Belts & • Are multiple belts under uniform tension and all of the same type
Pulleys • Are top surfaces of belts protruding above the pulley rims? Are the
bottoms any pulley groves shiny (indicating a worn belt or pulley)
• Are pulleys correctly aligned
• Are any chains stretched 9indicating worn out pins or bushings
Roller • Are any sprocket teeth worn, missing or damaged
chains • Is lubrication between pins and bushings sufficient
• Are sprockets correctly aligned
Shafts, • Is there any overheating, vibration, abnormal noise due to excessive
Bearings & play, or lack of greasing. Are any keys or set bolts loose or missing
Couplings • Are any couplings misaligned or wobbling, Are any seals worn out
• Are gears rightly lubricated with proper amount of lubricant.
Gears • Are any teeth missing, damaged worn out or jammed
• Is there any unusual noise or vibration
TPM Club India Page JH - 25  Confederation of Indian Industry
 Hydraulic checkpoints
• Is there correct quantity & level indicated for fluid in the reservoir
• Is fluid of correct Temp. And is min & max for temp. indicated
• Is fluid cloudy (indicating air entrapment
Hydraulic
• Are all fluid inlets & strainers clean, are any suction filters blocked
Checkpoints
• Are any fluid reservoir breather filters blocked
• Are fluid pumps operating without any unusual noise or vibration
• Are hydraulic pressure correct, and are operating ranges displayed
• Is any fluid or water leaking from fluid coolers or pipes
Heat
Exchangers • Are temp. differences between fluid & water inlets & outlets are correct ?
Are any tubes blocked
• Are there any fluid leaks ? Are hydraulic properly fastened?
Hydraulic
Equipment • Are hydraulic devices operating correctly without speed loss or
breathing? Are hydraulic pressure correct? And all gauges working
• Are all pipes and hoses fastened tightly?
Piping and • Are there any fluid leaks? Are any hoses cracked or damaged?
Wiring • Are all valves operating correctly? Is it easy to see whether valves are
open or closed/ Are any pipes, valves unnecessary?
TPM Club India Page JH - 26  Confederation of Indian Industry
 Pneumatic checkpoints
• Are FRLs clean? Is it easy to see inside of them? Are they fitted right way
around?
• Is there sufficient oil. And are the drains are clear?
FRLs • Is the oil dip rate correct ?(approx 1 drop for every 10 strokes)
• Are the FRLs installed not more than 3 m from the equipment?
• Are the pressure adjusted to the correct value and operating ranges are
clearly indicated?
• Is compressed air leaking from pneumatic cylinders or solenoids?
• Are all pneumatic cylinders and solenoid valves firmly fastened?
Pneumatic • Are any pistons dirty, worn, damaged?
Equipment • Are the speed controllers installed right way around?
• Is there any abnormal sound or overheating of solenoid valves, and are
any lead wires chafed or trailing?
• Are there any places in pneumatic pipes or hoses where fluid is liable to
Piping and collect? Are all hoses and pipes clipped firmly in place?
Wiring • Are any hoses cracked, damaged, are there any air leaks?
• Are valves operating correctly and open and close position known
TPM Club India Page JH - 27  Confederation of Indian Industry
 Electrical Checkpoints
• Are the interiors of distribution boards, switch boards, and control panels
kept clean, tidy, and well organized by the application of 5S activities?
Have any objects or flammable materials been left inside
• Is the wiring inside control panels in good condition? Are any wires coiled
Control or trailing?
Panels • Are all ammeters and voltmeters operating correctly?
• Are any switches, bulbs broken? Do all switches work correctly?
• Are panel doors in good condition? Do they Open & close easily?
• Are there any unused holes? Are control panels water& dustproof?

• Are all motors free of overheating, vibration, unusual noise & smell
Electrical
• Are al motor cooling fans and fins are clean?
Equipment
• Are any bolts loose? Are pedestals free of cracks and damages?
• Are all manual switches clean and free of damages & excessive play
• Are all switches installed in the correct position
Sensors • Are the interiors of limit switches is clean? Are any wires coiled or trailing?
• Are any limit switch dogs worn, deformed, or of the wrong shape?

TPM Club India Page JH - 28  Confederation of Indian Industry

 Electrical Checkpoints – Cont.
• Are all photoelectric switches and proximity switches clean and free
of excessive play?
Sensors • Are any sensors out of position? Are correct positions clearly
indicated?
• Are all lead wires un-chafed, and is insulation intact at entry points?
• Are all switches installed in the correct position
• Are all manual switches clean and free of damages & excessive
Switches play
• Are emergency stop switches installed in appropriate locations and
are they in good working condition?
• Are any pipes, wires, or power leads loose or unsecured?
• Are any ground wires damaged or disconnected?
Piping and • Are any pipes damaged or corroded? Are there any bare wires or
Wiring wires with damaged insulation?
• Are any wires coiled on the floor or dangling overhead?

TPM Club India Page JH - 29  Confederation of Indian Industry

 Checkpoints for General purpose Equipment

Pumps
Fans

TPM Club India Page JH - 30  Confederation of Indian Industry

 Tags
White Tag – Operator Red Tag – Maintenance

TPM TPM
1 2 3 4 5 1 2 3 4 5
Jishu-Hozen Step No. Jishu-Hozen Step No.

White efu Location of minor Red efu Location of minor

defects detected defects detected

Equipment name: Equipment name:

Control No. Control No.
Date of detection: Date of detection:
Detector: Detector:

Description of minor defects Description of minor defects

This sheet should be attached to equipment This sheet should be attached to equipment

TPM Club India Page JH - 31  Confederation of Indian Industry

 Abnormality - tag matrix
Abnormality
leads to
S Abnormality
n
o Exact description of location

TPM Club India Page JH - 32  Confederation of Indian Industry

 List of “Abnormalities” in the Equipment

Equipment Name : ______________________ Unit Name : ___________________________ No. : ______________

“Abnormality
Date of Why is it “Abnormality”?
“Abnormality” Why did it become so? Contents of the tag” Planned Date of
No. Detec- Detector (What will happen if it is Executor
Item (What is the cause?) Countermeasures Classifica- Date completion
tion left as it is?)
tion

TPM Club India Page JH - 33  Confederation of Indian Industry

 List of illustration of hard-to-access areas
Equipment Name : ______________________ Unit Name : ___________________________ No. : ______________
“Abnormality
Date of Items Cleaning
Contents of the tag” Planned Date of
No. Detec- Detector Lubrication Difficult Portions Difficult State Executor
Countermeasures Classifica- Date completion
tion Inspection
tion
C L R I

C L R I

C L R I

C L R I

C L R I
C L R I
C L R I
C L R I
C L R I
C L R I

C L R I
C L R I
C L R I
C L R I
C L R I
C L R I
C L R I
C L R I

TPM Club India Page JH - 34  Confederation of Indian Industry

 Step 2

Measures against Sources

TPM Club India Page JH - 35  Confederation of Indian Industry

 STEP 2
COUNTERMEASURES AGAINST SOURCES OF
CONTEMINATION AND HARD TO DO CLRI

• Countermeasures against sources of contamination

• Make approach easy for CLRI
• Make easy to do CLRI
• Shorten cleaning , lubricating time
• Adopt concepts of localized guards
• Ranking the priority places for daily cleaning

TPM Club India Page JH - 36  Confederation of Indian Industry

 Example of Activities Board
Leader Sub leader

Circle Members

Section and Subsection Themes !

Kobetsu-Kaizen
Policies Goals and
Measures
Reason for Selection Understand Present
status Jishu-Hozen Activity schedule

Accomplishment Indices
Overall Efficiency Troubleshooting and
*
Analysis Schedule Fuguai List

One-Point
Lesson

Performance Non Defe-ctive Effect

Availability Prevention of
Rate Rate
Recurrence, Remaining List of Doubts “Good to Find” Corner
problems
Photo

Before Before
Acceptance

Stoppage

Rework
Failure

Speed

Defect
Minor

Efu Attaching and Meetings

Number of Suggestions Removing Actual Work
Activities

TPM Club India Page JH - 37  Confederation of Indian Industry

 Step 3

Formulation of clean-up and

lubrication standards

TPM Club India Page JH - 38  Confederation of Indian Industry

 STEP 3 Prepare Tentative Standards

• Standards for cleaning, lubricating and tightening

• Standards are made by operators themselves with

guidance by PM

• Standards are made by using 5W 1H

• Standards should be easily understood by every one

• Introduce extensive visual controls

TPM Club India Page JH - 39  Confederation of Indian Industry

 TENTATIVE CLRI STANDARDS

Cell : Nozzle Cell Jishu - Hozen ( Tentative Cleaning, Lubrication and Inspection ) Standards

Equipment description : Micromatic OD Grinding Machine Equipment number : M12045 Cirlce name : NOZH 1

Person
Tools and Time Cycle During During
Illustration Classification No. Place or section Standards Method in
handling sec (month) operation stoppage
charge
Inspection 1 Tailstock With in the indicated Visual 2 W OP 
Tail stock
value range

Cleaning 2 Tailstock Free from mist & dust Waste cloth
 30 W OP 
Inspection 3 Table Lubrication With in the indicated Visual 2 W OP 
value range

Inspection 4 Loader Pistion No Damage Remove the 3mm 1200 1 M OP 
Pistion block Allenkey

Keys : D : Daily; W : Weekly; SC : Setting change; PM : Maintenance staff; OP : Operator.

TPM Club India Page JH - 40  Confederation of Indian Industry

 Step 3- Daily Check Sheet
Dept. / Unit: Mfg. - Hydraulic Equipment name: Fine Boring cell no 4 BI Plant no:1667-002 Month: September'01

TPM Monitoring of Tentative Standard for Cleaning, Inspection, Lubrication & Re-Tightening Step - 3
Assembly / Date
Line Sketch / Photo No Cat Look for Time
Part 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1
LOCATORS NO LOOSENESS
1 (8 NOS )
reT 15
OF MOUNTINGS
NO BURRS IN
C 5
LOCATING DIA

OIL LEVEL
2 COOLANT TANK I WITHIN 2
MIN/MAX LEVEL
4 2 3 COOLANT
OVER
M AX
3 MOTOR I
HEATING
5
PUMP UNIT
M IN
I UNUSUAL NOISE 5

ABNORMAL
I 5
COOLANT VIBRATION
TANK 4 MAGNETIC
OVER
CLARIFIER I 5
HEATING
GEAR BOX

I UNUSUAL NOISE 5

ABNORMAL
I 5
VIBRATION
TABLE LIMIT
NO LOOSENESS
5 SWITCH I 10
OF MOUNTINGS
DOGS (4
NOS)
SPINDLE
6 OVER
6 MOTORS I
HEATING
5
(2 NOS)

7 I UNUSUAL NOISE 5

ABNORMAL
I 5
VIBRATION
TABLE
5
7 BELTS (4 NOS) I BELT TENSION 15
3098

3098

3098

1339

3098

3098

3098

3185

3185

3185

3185

Operator clock number

Number : A ssy / Part Identification number in line sketch / photo Cat - Category ; C - Cleaning ; I - Inspection ; L - Lubrication ; reT - Retightening
Plan Completed

TPM Club India Page JH - 41  Confederation of Indian Industry

 Aiders : Visual controls

TPM Club India Page JH - 42  Confederation of Indian Industry

 VISUAL INDICATORS

Activity Symbol Tools

CLEAN

LUB
S
INSPECTION C
TPM Club India Page JH - 43  Confederation of Indian Industry
 VISUAL INDICATORS

Indication marks
Indication for
for nuts & bolts
valve controls

TPM Club India Page JH - 44  Confederation of Indian Industry

 VISUAL INDICATORS

Arrow sign for

Fan to indicate the
indicating the
function of Chiller Unit
rotating direction of
Motor

TPM Club India Page JH - 45  Confederation of Indian Industry

TPM Club India Page JH - 46  Confederation of Indian Industry
TPM Club India Page JH - 47  Confederation of Indian Industry
 JH STEP - STATUS INDICATOR

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

TPM Club India Page JH - 48  Confederation of Indian Industry

 Four Steps to Become An Operator Strong on
Equipment And Autonomous Maintenance

Autonomous Four steps to become

Maintenance an operator strong on
7 steps equipment

4 Master how to repair

7 All-out autonomous management
the equipment

6 Orderliness and tidiness Learn how to operate the equipment

3 with the required accuracy and how
to evaluate the product quality
5 Autonomous check-up
4 General inspection
2 Study the mechanism and functions of
3 Formulation of clean-up and lubrication equipment and machines
standards

2 Measures against sources of outbreaks Familiarize with the concept of equipment

maintenance and improvement and with
1
how to put the idea into practical
1 Initial clean-up realization
TPM Club India Page JH - 49  Confederation of Indian Industry
 Concept of “Jishu-Hozen”
Change in concept

Step 1 Defects and failures

Step 2 are the shame of
Step 4 Step 6
Step 3 the Production shop
Step 0 Step 5 Step 7

Effect Effect
Production
Change Operator’s
Motivation shop
equipment Reduced Change Zero defects
changes
defects and and failures
failures are realized

• Think and act • Rectify “Fuguai” Change in activities

• Positive challenge
for KAIZEN.
• Cleaning is inspection • Thoroughness of
• Process of • Inspection is a step to maintenance and
actions is head- find “Fuguai” management • Bottom up from circle
spring of • “Fuguai” should and activities
motives could be restored or • Autonomous KAIZEN
improved • Restoration and KAIZEN are a kind by operators
of success.
• Why does • Success is a pleasure as a result
forced of achievement
deterioration Enhance ability to find (Unless success can be expected,
occur ? and improve “Fuguai” the operators will not change their
• Needs of mind.)
“Jishu-Hozen

TPM Club India Page JH - 50  Confederation of Indian Industry