TPM

JH PILLAR

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 TPM
JH PILLAR
BACKGROUND

Chips & Scale

High Consumable cost spillage around
the Machine

More Breakdown occurrences Operator Equipment

due to poor operation/skill Why JH? knowledge is poor

More In house Defects

Max. Unsafe Conditions
& Rejection

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JH PILLAR
AIM

Objective of JH Pillar ….
1. To change the mind set of operator from ‘I Operate You Maintain’, to
‘I Operate I Maintain’.
2. To Achieve Zero Breakdown, Zero Defect, Zero Accident
3.To bring owner ship of machine operators
to take care of their equipment by themselves.

Timely doing of ……
C – Cleaning
L – Lubrication
I – Inspection
Rt – Re-tightening
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JH PILLAR

JISHU-HOZEN
(AUTONOMOUS MAINTENANCE)
“Jishu Hozen” is the activity in which each worker performs, i.e.
daily inspection, lubrication, troubleshooting, repair, accuracy
checks, and so forth on his own equipment, aiming at achieving the
goal of ‘keeping one’s own equipment’ in good condition by oneself.
Participation of production in maintaining
the machine condition is Jishu Hozen.
THE CHANGE THROUGH JH PRACTICE

I RUN IT, YOU FIX

IT
I RUN IT, I FIX IT
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JH PILLAR

Seven Steps of JH
0. The Beginning - preliminary step
1. Initial clean-up
2. Countermeasures against Sources of Contamination
And Difficult to Access Areas
3. Formulation of Tentative Standards
4. Overall Inspection
5. Autonomous Inspection
6. Standardization
7. Autonomous Management
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JH PILLAR

JH STEP 0 TO 3 - METHODOLOGY
1. 1S-2S around the machine .
2. Collecting machine history of breakdown, defect and accident.
Step 0
3. Team formation and work allocation.
4.Training given to operator.

1. Cleaning with inspection of equipment.

2. Seven types of Abnormality identification and tagging.
Step1 3. Fugai matrix preparation.
4. Tag stratification.
5. Audit for step-01 .

1. Counter measure on abnormality.

2. Before and after photograph.
Step 2 3. CLIRt time after step 2 countermeasures.
4. List of visual controls.
5. Audit for step-02.

1. Tentative standard preparation.

Step 3
2. Implementing visuals on machine.
3. Abnormality identification during practicing tentative standard .

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JH PILLAR

JH STEP 0

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JH PILLAR “ The Beginning”

• Form team Structure

• Collection of Breakdown, Accident & Defect data for all
machines
• Selection of machine for JH
• Activity plan( JH Time, Cleaning material Preparation etc.)
• Training on Seven Types of Abnormalities
• Training on 1S2S activity
• Explanation of Safety, Do’s & Don’ts during Step-1
• Training on Red & White Tag
• For easy understanding, Preparation of Block diagrams of
selected machine

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JH PILLAR DEFECT HISTORY
REJECTION REPORT FOR THE MONTH OF <NOV'2015>

LINE-630 TP

Regular As On Date D/O, 307, 19%

Parts :30.11.2015

REJECTION DETAILS
U/S, 6, 1%
REJ. PROD.
DIE NO % REJ.
Chopp QTY. QTY.
U/F C/S N/M M/TR B/LAP BEND S/P U/S D/O
ing S/P, 47, 3%
U/F

0 #DIV/0! C/S
Chopping, 38, 2% N/M
237 51 9 10 4 70 144 55844 0.26%

1123 8 9 11 2 11 41 7081 0.58% M/TR

1127 20 1 3 22 46 7162 0.64% BEND, 3, 0% B/LAP
1154 41 41 34363 0.12%
BEND
1175 25 7 5 3 36 28 22 126 8747 1.44% B/LAP, 172, 11% Chopping
1176 51 22 2 9 5 1 20 110 7271 1.51%
S/P
1177 53 2 3 3 3 11 75 6591 1.14%

M/TR, 5, 0% U/S
1178 169 8 1 1 6 10 195 7227 2.70%
D/O
1179 67 5 11 16 99 8391 1.18%

1184 10 1 5 16 634 2.52%

1187 3 3 729 0.41%

N/M, 55, 4%

1219 7 2 7 5 21 728 2.88%

U/F, 933, 58%
1221 227 1 61 3 28 320 12862 2.49%
C/S, 38, 2%

1229 245 9 11 1 22 33 2 1 43 367 18826 1.95%

total
933 38 55 5 172 3 38 47 6 307 1604 176456 0.91
nos.

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JH PILLAR BREAKDOWN HISTORY

1002 TON PRESS LINE CIRCULAR SAW BREAKDOWN DATA

TYPE OF DOWN DOWN

MACHINE BREAK DOWN
Reno DATE SHIFT PHYSICAL PHENOMENA FINAL ACTION ROOT CAUSE MAINT TIME IN TIME IN
NAME RELATED TO
(M/E/L/P/H/C) HRS Minutes

C/S Mist Oil Tank PM

1 7-Jun-13 II Oil not reaching at Blade Replaced Oil Pipe Line Poor Skill M 1.00 60
T- sune not done

Bearing Condition
C/S Ball Bearing 608 No.
2 25-Jul-13 I GFC Vice Clamping Problem Checking point not Poor Skill M 1.00 60
T- sune Changed.
taken in PM

Bearing rod
C/S GFC Roller Bearing
3 29-Jul-13 I Auto Mode Not working Checking point not Poor Skill M 0.91 55
T- sune Rod tightened.
taken in PM

New Mist Oil Nozzle Hole size

C/S
4 10-Sep-13 I Heavy Fumes Problem Modified Nozzle Not matching new Weak Design M 4.00 240
T- sune
fitted grade oil.

C/S Proximity Switch Natural

5 23-Nov-13 II Error Code No.37 problem Deterioration E 2.00 120
T- sune Changed Deterioration

Total 8.91 535

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JH PILLAR

JH INITIAL PREPARATION

HAND GLOVES, WIRE BRUSH

TOOL KIT COTTON
& CLEANING AGENT

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JH PILLAR JH STEP - 3 ACTIVITY PLAN

DEC'15
Sr.No. Activity
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
JH STEP -"0"
1
2 Selection of machine for JH Activity- past history collection of BAD
3 Preparation of activity plan for JH step - 3 completion
4 Explanation to understand Normal / Abnormal condition
5 Explanation of 7 types of abnormalities
6 Explanation of 1s & 2s activities in the cell
7 Explanation of safety, Do’s & Don’ts during JH step – 1
8 Explanation to put Red & White tag
9 Explanation of Equipment Structure with block diagram
Explanation of Hydraulic ,Pneumatic, Lubrication ,Fasteners &
10 Electricals & Electronics

11 JH STEP -"1"
12 Cleaning with meaning & Finding Abnormalities
13 Tag Matrix
14 Fugai Matrix/ Abnormality Stratification
15 List of Hard To Access Area
16 List of Sources of Contamination
17 List of Good To Find Cases
18 Step -1 Audit

JH STEP -"2"
19 Countermeasure on Sources Of Contamination
20 Countermeasure on Hard To Access Areas
21 Countermeasure on Good To Find Cases
22 Step-2 Audit
JH STEP -"3"
23 Tentative Standards preparation
24 Step-3 Audit 12
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JH PILLAR

“SEVEN” TYPES OF ABNORMALITIES

S.N. Abnormality Type Examples
Contamination, Damage, Abnormal phenomena, Play,
1 Minor Flaws Slackness, Adhesion, wear.

Nut bolts loose / missing, gauges dirty, No level

2 Unfulfilled basic conditions markings.

For cleaning, Inspection, Lubrication, Tightening,

3 Inaccessible Places Operation & Adjustment.

4 Contamination sources Product, Raw material, gases, Scrap, Others.

Foreign matter, Shock, Moisture, Vibration,

5 Quality defect sources Concentration, Viscosity.

Unnecessary & Machinery, Piping, Measuring instruments, Spare parts,

6 Electrical equipments.
non-urgent items

7 Unsafe places Lights, Floors, Rotating machinery, Steps, Lifting.

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JH PILLAR
EXAMPLES OF ABNORMALITIES

UNFULFILLED BASIC INACCESSIBLE PLACES – HARD

MINOR FLAWS – DUST ON TO CLEAN & INSPECT UNNECESSARY & NON-
CONDITIONS – (INDICATOR
MOTOR FAN LUBRICATION UNIT DOWN IN URGENT ITEMS
MISSING)
MACHINE

QUALITY DEFECT SOURCES: CONTAMINATION SOURCES

UNSAFE PLACES - OPEN
PITTING MARKS ON – CHIPS & DUST BELOW
CHAIN DRIVE
BALLSCREW MOTOR
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JH PILLAR

4. DO’S & DON’T DURING JH

DO'S
USE PPE’S (PERSONAL PROTECTIVE EQUIPMENTS) LIKE HAND GLOVES, GOGGLE, MASK ETC. WHILE
WORKING.

SWITCH OFF THE ELECTRICAL SUPPLY BEFORE OPENING THE PANEL COVER.

SHUT OFF AIR SUPPLY VALVES & DRAIN AIR FROM FRL.

IN CASE OF DOUBT PLS. ASK THE MAINTENANCE PERSON FOR SAFETY PRECAUTIONS

DON’Ts

DO NOT USE COMPRESSED AIR FOR CLEANING.

DO NOT WORK WITHOUT SAFETY EQUIPMENT.

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JH PILLAR

RED & WHITE TAG

WHITE
RED TAG TAG

Red tags to be removed with the help of White tags to be removed by production
Maintenance circle members. Circle members .
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JH PILLAR

M/C Block Diagram

Press Shop
Machine Name : TSUNE GL 72 Circular Saw Cutting Machine
6
No. Sub-Assly. Name Function
To provide raw bars for cutting and
Bar Loading Mechanism
1 automatic loading of bar

Contains electrical circuits & switches to

Control panel
5 2 start the machine operations

To control operation setting and change

Operating Panel
3 parameter

1 4
Cutting Blade To Cut bar in required length

4 Front Side of Machine

Provide access for cleaning and removing
5 of chips
2 To provide mist oil for cutting blade as
7 6
Mist Oil Tank
lubricant
3 Hydraulic Pack
To provide supply of hydraulic oil for
7 clamping

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JH PILLAR

JH STEP 1

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JH PILLAR
INITIAL CLEAN-UP

1. Abnormality Matrix

2. Fugai Matrix

3. Good to find cases

4. One Point Lesson

5. Sources of Contamination (SOC)

6. Hard to Access Areas (HAA)

7. Step-1 Audit

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JH PILLAR

Initial Cleaning

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JH PILLAR

Abnormalities Tagged
• As per picture,
electric board is
open and hence an
abnormality.
• It is an Unsafe place
to work.
• Red tag indicates
action from
maintenance team is
required. 21
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JH PILLAR
Abnormalities Tagged
TPM(Total Productive Maintenance)
Abnormality/Fugai Tag Matrix
PLANT/DEPPT.
CIRCLE NO./NAME/M/c : 630 T FORGING PRESS CIRCLE LEADER: MONTH : DEC - 15
:Ranjangone/Press Shop

Tag Tag Abnormality

Abnormality Type Color Leads to
Classification

Unfulfilled basic cond.

Contamination sources
Abnormal movement

Difficult to access

Unsafe Condition
Sr. No.

Non Urgent item

Broken/damages

Abnormal Noise
Splash/Spillage
Sub Part

Quality Defect

Quality <NC>
Discoloration

Unnecessary/

Cost Increase
Not working

Minor Flaws
Date Area Fugai item / Abnormality

Excess Heat
REMARKS

Breakdown
Holes/ gap

Vibration
Chipping

Hanging
Assy Name

Missing

Unsafe
Power
White
Other

Other
Wear
loose
Leak

Bent
Dirt

Red
Operating
Press Shop
Panel
Main cable dirty To be clean
1 21/12/15 630 F/P
Operating To be re
Press Shop
Panel
Main cable of operating panel not properly routed
2 21/12/15 630 F/P routed
Operating
Press Shop
Panel
Cables inside panel dirty To be cleaned
3 21/12/15 630 F/P
Operating
Press Shop
Panel Cable routing inside operating panel box not proper To be fix
4 21/12/15 630 F/P
Operating
Press Shop
Panel Main motor current guage dirty To be cleaned
5 21/12/15 630 F/P
Operating
Press Shop
Panel Main motor current gauge loose To be fix
6 21/12/15 630 F/P
Operating
Press Shop
Panel
Switches on panel dirty To be cleaned
7 21/12/15 630 F/P
Operating
Press Shop
Panel
Accept/Reject switch on operating panel broken To be change
8 21/12/15 630 F/P
Operating Indicator labels on operating panel for various
Press Shop
Panel
To be fix
9 21/12/15 630 F/P switches not visible
Grease
Press Shop Lubrication Grease supply pipe dirty To be clean
10 21/12/15 630 F/P tank
Grease
Press Shop Lubrication Heavy leakage from lub. pipe To be replaced
11 21/12/15 630 F/P tank
Grease
To be place
Press Shop Lubrication Grease lubrication tank not properly placed
tank properly
12 21/12/15 630 F/P

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JH PILLAR

Fugai Matrix
Circular Saw ( 1002 T Press Line ) 70
59 Tag Put
Tag Quantity Total Quantity
60 53 54 Tag Removed
48 Tag Pending
50

Tag Quantity
WHITE TAGS 5
59 40
RED TAGS 54
30
WHITE TAGS REMOVED 5
53
20
RED TAGS REMOVED 48 10 6 6 5 5
0
WHITE TAGS PENDING 0 0
6
RED TAGS PENDING 6 Total Tag Red Tag White Tag

• Fugai matrix is nothing but Tag summary

• Fugai matrix shows Red and White tag
status of machine

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JH PILLAR

GOOD TO FIND Circular Saw 1002 T Press Line

It may led to if
Sr No Detector Observed condition Action Taken
not attended
Bar Loader Roller 3 Nos. Break Down / Spring washer
1 Bhosle
Fixing bolt loose Accident provided for locking
Hydraulic cylinder oil Break down / Properly routed with
2 Hogade
supply pipe hanging Cost fixing clip
Solenoid coil supply Supply cable properly
3 Gosavi Break Down
cable damage Rooted with gland

Bar clamping supply Supply cable properly

4 Wadekar Break Down
cable hanging Rooted with gland
Air pressure gauge
5 Gosavi Break Down Gauge Replaced
damage

• While cleaning with meaning we

might found some abnormalities
which in future leads to breakdown/
Accident
• These cases are called as Good to
find cases

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 TPM
JH PILLAR Step 1 Audit
ijaSau haoJaona (J.H.)Aa^Taonaa^masa maoMTonansa
sTop 1 : Aa^iDT iSaT
iDpaT-maoMT: sak-la cao naava : Aaa^proTrcao naava :
Aaa^iDT kaoNaI Gaotlao : Aaa^proTr jao.eca.iplar caoArmana Ta^p ma^naojamaoMT
paHa gauNa ( @vaalaIfayaIMga skaoAr) 85 75 70
Aa^iDT tarIK :
gauNa
pasa/naapasa
Aa^iDT GaoNaayaacao naava va sahI.
sTop - 1 T@kovaarI %

gauNa imaLalaolao gauNa

AayaTma vaNa-na jao.eca. caoArmana
vaa[-T ApuNa- spYT Anaukula ]%kRYT Aaa^proTr Aa^iDT Ta^p ma^naojamaoMT Aa^iDT
Aa^iDT
a) maiSanacao gaaD-\sa, pa[-p, vaayar, yaaMcyaavar ga`Isa, Aa^[-la AaiNa GaaNa nasaavaI tsaoca to
D^maoja Jaalaolao nasaavaot. 1 2 3 4 5
maiSanacyaa baahya AMgaacaI svacCta
1 b) sava- ivakRtI (A^banaa^ima-laITIja\) (ilakoja, isplaoja, lauja, D^maoja, ba`aokna,
(i@lainaMga Aa^^f maiSana maona baa^DI)
imaisaMga ,Aaovhr, ihT SaaoQauna kaZuna %yaavar T^ga laavalaolaa Asaavaa.(roD / vha[-T) 1 2 3 4 5

a) maiSanacyaa saba AsaoMmblaIvar (p`a^@JaIimaTI, maaoTar, ispMDla, vaayar, vha^lvh, gaojaosa,

maiSanacyaa AtrMgaacaI svacCta pa[-Psa, p^nala, baa^@sa, isTrr) gaI`sa Aa^[-la AaiNa GaaNa nasaavaI. 2 4 6 8 10
(nyaumaoTIk, hayaD/aolaIk, [laokT/Ikla,
2
yauTIlaITI, laa[-nsa, A^nD lauiba`koSana b) sava- ivakRtI (A^banaa^ima-laITIja) (ilakoja, isplaoja, lauja, D^maoja, ba`aokna,
erIyaa) imaisaMga ,Aaovhr, ihT SaaoQauna kaZuna %yaavar T^ga laavalaolaa Asaavaa.(roD / vha[-T) 2 4 6 8 10

a) maiSanacyaa AajaUbaajaUlaa AnaavaSyak vastU zovalyaa nasaavyaat AaiNa

[nspokSana Tobala, maojarIMga [MsT/umaoMTsa, gaojaosa, sarfosa, PlaoT, baaoD-sa, knvhoAsa- kòna
[%yaadIvar QauL, iga`sa, Aa^[-la AaiNa GaaNa nasaavaI. 1 2 3 4 5
maiSanacyaa AajaubaajauMcaI AaiNa sauTyaa
3
BaagaaMcaI svacCta b) caalaNyaacaI AaiNa kama krNyaacaI jaagaa namaUd kolaolaI Aaho ka ? ra^ ^maToiryala
ifnaISa maToiryala AaiNa sk`^p yaaMcyaasaazI vaogaLI jaagaa namaUd kolaolaI Aaho ka 1 2 3 4 5
?

Note
1.Aa^proTrcao Aa^DIT pasa kolyaavarca jao.eca.caoArmananao Aa^DIT kravao.
2.jao.eca.caoArmananao Aa^DIT pasa kolyaavarca Ta^p ma^naojamaoMTnao Aa^DIT kravao.
3.sTop - 1 cao Aa^DIT pasa Jaalyaavarca sTop - 2 cao Aa^DIT Gyaavao
4. p`%yaok Aa^DITrnao %yaalaa dSa-valaolyaa BaagaamaQyaoca gauNa laIhavaot.
5. kahI inairxaNa ilahvaayacao Asalyaasa SaovaTcyaa panaavarIla KalaI idlaolyaa jaagaovar laIhavao. 25
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JH PILLAR

JH Step-2

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JH PILLAR

Countermeasures on Sources of Contamination

• Sources of contamination is nothing but origin of dirt

• For ex. Mist oil spillage on ground from blade, burr
spread allover machine
• Source of contamination can be found while cleaning
machine in this step 1.

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JH PILLAR

• Countermeasures on Hard to Clean Areas

– Hard to clean are the areas where cleaning is not
possible easily and can be the source of
contamination
– For Ex.
– 1)burr accumulation on clamping
– 2) Dust accumulation on hydraulic tank top side

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JH PILLAR

• Countermeasures on Hard to Access Areas

– HTA are the machine places where human cant
reach easily for any work
– For Ex.
– 1) Oil top-up on hydraulic tank
– 2) Oil top up on cutting oil tank

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JH PILLAR

• Countermeasures on Hard to Inspect Areas

– HTI are places where operator can’t inspect
various machine parameters easily.
– For Ex.
– 1) Hydraulic pressure gauge
– 2)Cutting oil level indicators etc.

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JH PILLAR

For Ex. Hard to CLIRT data

HARD TO CLEAN Circular Saw 1002 T Press Line
Sr No Difficult Area Action
1 Motor & Gear box top side dirty. Top side acrylic sheet provided
2 Dust Accumulation on Hydraulic Tank top side. Covered by M.S. Plate

HARD TO INSPECT Circular Saw 1002 T Press Line

Sr No Difficult Area Action
1 Air pressure Gauge Damage & Fixed to Difficult Position Gauge to be changed & to be Shift to Operator side
2 Hydraulic level indication Hydraulic tank shift to operator side
3 Hydraulic oil pressure gauge Pressure gauge to be shifted to Operator side
4 GFC voice clamping pressure gauge Pressure gauge to be shifted to Operator side
5 Main voice clamping pressure gauge Pressure gauge to be shifted to Operator side
6 Main Air pressure gauge Pressure gauge to be shifted to Operator side
7 Cutting oil level indication Transparent Flow pipe provide

HARD TO LUBRICATE Circular Saw 1002 T Press Line

Sr No Difficult Area Action
1 Oil top up on Hydraulic Oil Tank Hydraulic tank shift to operator side
2 Oil top up on Cutting Oil Tank Small bottle to be arranged

HARD TO RETIGHTENING Circular Saw 1002 T Press Line

Sr No Difficult Area Action
1 End piece extractor hydraulic cylinder loose Tightened with spring washer & lock marking done
2 Roller fixing bolt loose Tightened with spring washer & lock marking done

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 TPM
JH PILLAR Step 2 Audit
JISHU HOZEN (AUTONOMUS MAINTENANCE)
sTop 2: GaaNaIsa karNaIBaut GaTk AaiNa saI.ela\.Aaya,.Aar.TI.krNyaasazI AvaGaD jaagaa yaaMvarIla ]payayaaojanaa
iDpaT-maoMT: sak-la cao naava : Aaa^proTrcao naava :
Aaa^iDT kaoNaI Gaotlao : Aaa^proTr jao.eca.iplar caoArmana Ta^p ma^naojamaoMT
paHa gauNa ( @vaalaIfayaIMga skaoAr) 85 75 70
Aa^iDT tarIK :
gauNa
pasa/naapasa
Aa^iDT GaoNaayaacao naava va sahI.
sTop - 2 T@kovaarI %

gauNa imaLalaolao gauNa

AayaTma vaNa-na Aaa^proTr jao.eca. caoArmana
vaa[-T ApuNa- spYT Anaukula ]%kRYT Ta^p ma^naojamaoMT Aa^iDT
Aa^iDT Aa^iDT
a) sTop.1 nausaar svacCtocaI patLI AaiNa vaoLapHaka naUsaar svacCta zovalaI Aaho.
1 2 3 4 5
b) sava- Abana^arimalaITIja inayaimatpNao SaaoQauna %yaavar T^ga laavalaa jaat Aaho ka ?
1 2 3 4 5
1 sTop.1 caI doKBaala
c) sTop.1 kRtI AaraKDyaap`maaNao (A^@Sana Pla^na ) paMZro laala T^ga kaZlao Aahot ka
? hvaa AaiNa tola yaaMcaI Saunya gaLtIcaI patLI gaazlaI Aaho ka ? AsaurxaIt
2 4 6 8 10
prIisqatIMnaa AaoLKuna %yaaMnaa naYT kolao Aaho ka ? [-napuT Aa]TpUT maTorIyala AaiNa
AajaubaajaucaI jaagaa yaaMnaa icanhakIMt kolao Aaho ka ?
a) GaaNaIsa karNaIBaut Asanaa-yaa sava- GaTkaMvar ]payayaaojaNaa kolaI Aaho ka ? (QauL,
saMpuNa- BaagaaMcaI / ivaBaagaatIla jaagaocyaa ivakRtIvarIla
2 GaaNa, isplaoja, hvaa, tola gaLtI) 3 6 9 12 15
]paya yaaojanaa
a) i\ @lainaMga lauiba`koSana [nspo@Sana AaiNa rITa[TinaMga saaopo vhavao yaasaazI kahI sauQaarNaa
kolyaa Aahot ka ? 1.vaayar ra]TinaMga kolaI Aaho ka ?
2.sava- pa[-Psa if@sa kolao Aahot ka ? 3.naT baaolTvar salagnatocaI maakI-ga
3 paohaocaNyaasaazI AvaGaD jaagaosaazI ]payayaaojanaa. kolaI Aaho ka ? 4.sapuNa- jaagaovar ihrvaa
3 6 9 12 15
AaiNa laala rMga dSa-valaa Aaho ka ?
5. pa[-Psa maanaka nausaar (sT^nDD- nausaar ) klar kolao Aaho ka ?
Note
1.Aa^proTrcao Aa^DIT pasa kolyaavarca jao.eca.caoArmananao Aa^DIT kravao.
2.jao.eca.caoArmananao Aa^DIT pasa kolyaavarca Ta^p ma^naojamaoMTnao Aa^DIT kravao.
3.sTop - 1 cao Aa^DIT pasa Jaalyaavarca sTop - 2 cao Aa^DIT Gyaavao
4. p`%yaok Aa^DITrnao %yaalaa dSa-valaolyaa BaagaamaQyaoca gauNa laIhavaot.
5. kahI inairxaNa ilahvaayacao Asalyaasa SaovaTcyaa panaavarIla KalaI idlaolyaa jaagaovar laIhavao.

gauNa imaLalaolao gauNa

AayaTma vaNa-na Aaa^proTr jao.eca. caoArmana
vaa[-T ApuNa- spYT Anaukula ]%kRYT Ta^p ma^naojamaoMT Aa^iDT
Aa^iDT Aa^iDT
a) jao eca kayaJaona SaIT 1 2 3 5
4 maaihtI ivaSlaoYaNa va kRtI yaaojanaa p`dSa-na b) vana pa[-nT laosana (ek ibaMdU QaDo) 1 2 3 5 32
c) baIfaor AaFTr faoTaoja\ 2 4 6 8 10
 TPM
JH PILLAR

JH Step-3

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JH PILLAR

FORMULATION OF TENTATIVE STANDERD

1. PREPARE JH ROUTE MAP & MARK LOCATIONS
2. PREPARE TENTATIVE STANDARDS FOR MACHINE &
START PRACTISING
3. PROVIDE VISUALS ON ASSEMBLIES, SUB ASSEMBLIES
& PARTS
4. FINDING THE ABNORMILITIES & REMOVAL DURING
DAILY JH TIME
5. DAILY MONITORING OF RESULTS
6. JH STEP 3 AUDIT BY TEAM LEADER WITH EQUIPMENT
OWNER
7. JH STEP 3 AUDIT BY JH CHAIRMAN & TOP
MANAGEMENT
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JH PILLAR Tentative Standard

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 TPM
JH PILLAR Visual Explanations

B D
BREAKDO DEFEC T
WN

INSPECT IF NOT DONE IF NOT DONE KAIZEN DO DAILY DO WEEKLY DO

VISUALLY BREAKDOWN DEFECT WILL DONE MONTHLY
WILL OCCURE
OCCURE

CLEAN HEAR RETIGHTEN LUBRICATE FEEL THE FEEL

ABNORMAL IF LOOSE VIBRATION TEMPERATUR
NOISE E OR
VIBRATION

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JH PILLAR

How to put
visuals for
single check
point

1.1 B
BREAKDOWN

Check What to do What What will happen

point frequency if not done
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 TPM
JH PILLAR Step 3 Audit
JISHU HOZEN (AUTONOMUS MAINTENANCE)
sTop 3 : saI.ela.Aaya.Aar.TI.krNyaasaazIcao ta%purto maanak ³sT^NDD-´
iDpaT-maoMT: sak-la cao naava : Aaa^proTrcao naava :
Aaa^iDT kaoNaI Gaotlao : Aaa^proTr jao.eca.iplar caoArmana Ta^p ma^naojamaoMT
paHa gauNa ( @vaalaIfayaIMga skaoAr) 85 75 70
Aa^iDT tarIK :
gauNa
pasa/naapasa
Aa^iDT GaoNaayaacao naava va sahI.
sTop - 2 T@kovaarI %

gauNa imaLalaolao gauNa

AayaTma vaNa-na
vaa[-T ApuNa- spYT Anaukula ]%kRYT Aaa^proTr Aa^iDT jao.eca. caoArmana Aa^iDT Ta^p ma^naojamaoMT Aa^iDT
a) sTop.1 nausaar AarMiBak svacCtocaI patLI AaiNa sauQaarnaaMcaI doKBaala naIT zovalaI Aaho kaÆ
1 2 3 4 5
1 sTop.1 doKBaalacaI isqatI b) sTop.2 nausaar GaaNaIsa karNaIBaut zrlaolyaa GaTkaMvar kolaolyaa sauQaarNaaMcaI doKBaala zovalaI Aaho kaÆ
1 2 3 4 5
svacCtosaazI cao maanak ³sT^NDD-´
a) ]pkrnaacI saMrcanaa AaiNa sqaana yaanausaar maanak(Standard)tyaar kolao Aaho ka?
1 2 3
]pkrNaacyaa maulaBaut doKroKIsaazI kRtI maanak AaiNa b) svacC krNyaasaazIcyaa jaagaa spYTpNao namaud kolyaa Aahot ka? 1 2 3
%yaacaI garja.(saI.ela.Aaya.AarTI) c) svacCtocaI pdQat AaiNa saaQanao inado-iSat kolaI Aaho ka\? 1 2 3
d) svacCtosaazI laagaNaara vaoL namaud kolaa Aaho ka? 1 2 3
vaMgaNa maanak (lauiba`koSana sT^DD-)
a) kaoNa%yaa p`karcao vaMgaNa lauiba`kMTsa kaozo ksao AaiNa iktI vaaprayacao ho inado-iSat kolao Aaho ka?
1 2 3 4
b) vaMgaNa ibaduMnaa (lauiba`kTsa pa^[-Tsa) AQaaoroKaIt (laobala)laavalao Aaho ka? 1 2 3 4
c) kaoNa%yaahI vaoLI lauiba`koSana krNyaasaazI Aa^[-la ]plabQa Aaho ka? 1 2 3
2 d) tola (Aa^[-la) saMcaya (sTaoroja) sqaana inaTnaoTko Aaho ka? 1 2 3 4
tpasaNaI maanako ([nspo@Sana sT^DD-sa)
a) tpasaNaIsaazI cao sava-sqaana vaarMvaarta if`@vaMsaI pdQat AaiNa jabaabadarI inaid-YT Aaho ka?
1 2 3
ir Ta[-TinaMga maaNako (ir Ta[-TinaMga sT^DD-sa)
a) baaolTsa/naTsa yaaMcaI saM#yaa, irTa[-TnaIMgacaI pdQat, vaarMvaarta (if`@vaonsaI), AaiNa irTa[-TnaIMgacaI saaQanao
inado-iSat kolaI Aahot ka? 1 2 3

b) naT/baaolTsa saOla lauja Aahot ka? kaonata naT/baaolT gaLuna pDlaa Aaho ka 1 2 3 4
c) ir Ta[-TinaMgasaazI AvaGaD Asalaolyaa jaagaovar naT/ baaolTsacaI tpasaNaI ([nspo@Sana) krNyaasaazI kahI
icanhaMkna kolao Aaho ka? 1 2 3

a) maanakamaQaIla p`%yaok gaaoYT spYT AaiNa savaa-Mnaa samajaola ASaI Aaho ka? 1 2 3 4 5
b) saI.ela.Aaya.Aar TI krNaosaazI maiSanacao sava- Baaga icanhaMikt (maaik-Mga) kolao Aahot ka?
sTop 3 maanak sT^DD- tyaar krNaosaazI Aa^proTrcaI Bauimaka 1 2 3 4 5
3
AaiNa jaaga$kta c) maanakanausaar (sT^DD-nausaar) maiSanacaI doKBaala kolaI jaat Aaho ka? 1 2 3 4 5
d) saaoPyaa pdQatInao tpasaNaI haoNaosaazI nava-naivana klpnaa saik`ya pNao laagau haot Aaho ka?
1 2 3 4 5
Note
1.Aa^proTrcao Aa^DIT pasa kolyaavarca jao.eca.caoArmananao Aa^DIT kravao.
2.jao.eca.caoArmananao Aa^DIT pasa kolyaavarca Ta^p ma^naojamaoMTnao Aa^DIT kravao.
3.sTop - 1 cao Aa^DIT pasa Jaalyaavarca sTop - 2 cao Aa^DIT Gyaavao
4. p`%yaok Aa^DITrnao %yaalaa dSa-valaolyaa BaagaamaQyaoca gauNa laIhavaot. 38
5. kahI inairxaNa ilahvaayacao Asalyaasa SaovaTcyaa panaavarIla KalaI idlaolyaa jaagaovar laIhavao.
Journey Continues......

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