Professional Documents
Culture Documents
1. ABSTRACT
2. INTRODUCTION
3. MAINTENANCE
4 . T O T A L P R O D U C T I V E M A I N T E N A N C E ( TP M )
5. PILLARS OF TPM
6 . J I S H U H O Z E N ( A M)
7. THREE SKILLS
8. IMPLIMENTATION OF AM
11. CONCLUSION
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2. INTRODUCTION
2.1 MAINTENANCE
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3. TOTAL PRODUCTIVE MAINTENANCE
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4. PILLARS OF TPM
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5. JISHU HOZEN
(AUTONOMOUSMAINTENANCE)
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clear that this way of thinking does not promote optimal
equipment performance.
While these tasks are easy enough to do, in very few factories are
they done well. Often you can find clogged drains, empty oil
supply equipment, and other results of neglect.
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When you have mastered all three skills, you will understand the
equipment well enough to recognize the causes of future
problems. You will realise when the machine is about to produce
defects or break down. You will also be able to respond quickly.
The following list describes some of the skills operators' need.
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The ability to understand the relationship between equipment
and quality, and the ability to predict problems in quality and
detect their causes
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From the traditional organization split between users (production)
and tenders (maintenance), the new thinking way is focusing on
polyvalent teams made of users and tenders, skills idealy found in
the same persons.
Obviously, anyone who masters all these skills has achieved a very
high level indeed, and no one is expected to do hat quickly. Instead,
each skill should be studied and practiced for whatever time it takes
to acquire proficiency.
5.3 Policy:
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6 IMPLEMENTATION OF AUTONOMOUS
MAINTENANCE
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Seven Steps for Developing Autonomous
Maintenance
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2.Eliminate Eliminate the Increase inherent learn equipment
sources of sources of dirt reliability of improvement
contamination and debris; equipment by concepts and
and inaccessible improve preventing dust and techniques, while
areas accessibility of other contaminants implementing
areas that are from adhering and small-scale
hard to clean accumulating improvements
and lubricate; Enhance Learn to
reduce time maintainability by participate in
required for improving cleaning improvement
lubrication and and lubricating through small
cleaning group activity
Experience the
satisfaction of
successful
improvements
3.Develop Set clear Maintain basic Understand the
cleaning and cleaning, equipment meaning and
lubrication lubrication and conditions(deterior importance of
inspection ation- preventing maintenance by
standards that activities) cleaning, setting
can be easily lubrication, and maintaining our
maintained over inspection own standards
short intervals; (What is
the time allowed equipment
for control?)
daily/periodic Become better
work must be team members by
clearly specified taking on more
responsibility
individually.
4.Conduct general Conduct training Visually inspect Learn equipment
inspection skills on inspection major parts of the mechanisms,
training skills in equipment; restore functions, and
accordance with deterioration;enhan inspection criteria
inspection ce reliability through inspection
manuals; find Facilitate training, master
and correct inspection through inspection skills
minor defects innovative Learn to perform
through general methods, such as simple repairs
inspections;modi serial number Leaders enhance
fy equipment to plates, colored leadership skill
facilitate instruction labels, through teaching
inspection thermotape gauges group members
and indicators see learn through
through covers etc. participation
Sort out and study
general inspection
data;
Understand the
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importance of
analyzed data.
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6.Organize and Standardize Review and Broaden the scope
manage the various improve plant of autonomous
workplace workplace layout etc. maintenance by
regulations;impr Standardize control standardizing
ove work of work-in-process various
effectiveness,pro defective products, management and
duct quality, and dies, jigs, tools control items
the safety of the measuring Be conscious of
environment instruments, the need to
Reduce setup material handling improve standards
and adjustment equipment, aisles, and procedures
time; eliminate etc. continuously,
work-in-prices Implement visual based on a
Material control systems standardization
handling throughout the practice and actual
standards on the workplace data analysis
shop floor Managers and
Collecting and supervisors are
recording data: primarily
standardization responsible for
Control continuously
standards and improving
procedures for standards and
raw materials, procedures and
work-in-process, promoting them on
products, spare the shop floor
parts, dies, jigs,
and tools
7.Carry out Develop Collect and analyze Gain heightened
ongoing company goals; various types of awareness of
autonomous engage in data; improve company goals and
maintenance and continuous equipment to costs (especially
advanced improvement increase reliability, maintenance costs)
improvement activities;improv maintainability and Learn to perform
activities e equipment ease of operation simple repairs
based on careful Pinpoint through training
recording and weaknesses in on repair
regular analysis equipment based on techniques
of MTBF analysis of data, Learn data
implement collection and
improvement plans analysis and
to lengthen improvement
equipment life span techniques
and inspection
cycles
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GOALS AND OBJECTIVES OF AUTONOMOUS
MAINTENANCE
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CASE STUDY OF AUTONOMOUS
MAINTENANCE
ABSTRACT
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problems occurred on the machine and indirectly reduced the cost
of breakdown maintenance.
INTRODUCTION
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Autonomous Maintenance (AM), called as Jitshu Hozen in
Japanese. The success of TPM, to a large extent, depends upon
the success of AM. Grinding machine is extensively used in the
Machine Shop Laboratory (MSL), Universiti Teknikal Malaysia
Melaka (UTeM) to perform the task given especially in
manufacturing practice subject. The machine is exposed to the
breakdown as it is not well maintained.
GRINDING MACHINE
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The technical data of Grinding Machine BO 300 A is shown in
Table 1.
Specifications
External and internal diameter and width of 300 / 76 - 40 mm
grinding wheels
Wheel spindle speeds 1600 Rev / min
Outputs and revolutions of the main driver motor 2.2, 1440 kW, rev /
min
DATA COLLECTION
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yellow tag used for simple fuguai which not required highly
technical knowledge. Figure 1a and 1b are the example of fuguai
tag which used for data collection. The following are the
descriptions of the items on the fuguai tag.
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Inspection checklist was applied. Table 2 describe the inspection
checklist for data collection.
No Inspection Description
Remark
1 Look:
� Have chips or coolant contaminates the motor?
Yes
2 Listen:
� Are there any strange noises (whining? groaning?
sound or slippage?) from the motor brake, or belts?
No
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FUGUAI CHARACTERISTIC
There are eight fuguai that have been identified on the Grinding
Machine (Model: BO 300A) including dust, coolant spill,
corrosion, cobweb, scratches, broken hose, misspelled label and
misplace items (see table 3 for details). The declaration of
criteria for each fuguai is important because when one fuguai is
found, due to its characteristics, the fuguai could be classified to
its class / type.
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7. Misspelling: LabelExample: the spelling of “PEDELSTAL” is
wrong. It should be spelled as “PEDESTAL”.
8. Misplace item: The item that should not place on the area.
FUGUAI ANALYSIS
For analysis purpose, bar chart and trend chart were used. The
charts are used to summarise the result in proper way for
comparison and similarity analysis. Figure 2 represent the data
collection for front view, Figure 3 for right view meanwhile
Figure 4 represent left view.
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Figure 2c, 3c and 4c shows the trend analysis on 7 weeks fuguai
observation on the machine. For the knowledge, through this
study every identified fuguai on the previous week will be
eliminated before proceed to the next observation except red tag
fuguai which required highly skill and knowledge. This is very
crucial to analyse the trend of the fuguai towards autonomous
maintenance programme. The trend charts show that most fuguai
are found on week 1 for all areas. Without machine user
awareness on the machine maintenance and the fuguai, the
physical fuguai was dramatically rising until week 5.
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CONCLUSION
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Furthermore this project is not applicable for other types of
grinding machine. When performing AM on the machine, the
importance of AM have become more apparent and radiance.
Performing AM on the machine has built the awareness that even
a tiny abnormalities on the machine could lead to the large impact
on machine performance. Moreover, after performing Initial
Cleaning on the machine, the workplace area became clean,
uncontaminated, organized, and user-friendly.
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Conclusion
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