04 BirlaTyres

8/22/2019 04 BirlaTyres

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5th TPM National Conference

Session B : Jishu Hozen

(Autonomous Maintenance)

Topic :JH Step 1-4

Presentation by

Mr Pravas Kumar Mohapatra

Dy Manager

Birla Tyres


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5th TPM National Conference Page 4.1

Birla Tyres JH Step 1-4

A PRESENTATION ON"JISHU-HOZEN"

TYRESTYRESTYRESTYRESBIRLABIRLABIRLABIRLA

B K BIRLAGROUP OF COMPANIESB K BIRLAGROUP OF COMPANIESB K BIRLAGROUP OF COMPANIESB K BIRLAGROUP OF COMPANIES

BKBI

RLA

GROUPO

F

COMPA

NIES

TPMTPMTPMTPM

Product No. of Plants

01

01

01

01

01

01

02

03

03

04 05

05

05

05

06

07

0809

10

11

12

12

12

12 13

1414

05

Cement 6

Heavy Chemicals 1

MDF Board 2

Paper 1

Plantation 5

Polymerisation 1

Rayon 1

Refractories 1

Spun Pipe 1

Shipping 1

Tech. Institute 1

Textile 4

Tyre 1

Yarn TyreCord 2

Total 28

01

02

03

10

11

12

13

14

04

05

0607

08

09

Group Worth: Rs. 45,000 million

Employees : 40,000

AREA OF BUSINESS OF B.K. BIRLA GROUP OF COMPANIES

OUT LINE OF OUR GROUP


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TPMTPMTPMTPMHISTORY OF BIRLA TYRES

.

.

.

.

.

.

.

.

.

.

2004-OSHAS-18000 & SA-8000 CERTIFICATION

2001-CERTIFICATION OF CALIBRATION LAB. BY NABL

2000-TPM EXCELLENCE AWARD FIRST CATEGORY

1999-QS 9000 QUALITY MANAGEMENT SYSTEM

(SYSTEM FOR AUTOMOBILE INDUSTRY)

1998-ISO 14000 ENVIRONMENT MANAGEMENT SYSTEM

1994-ISO 9001 QUALITY MANAGEMENT SYSTEM

73 STOCK POINTS-DISTRIBUTION NETWORK ALL OVER COUNTRY

25 %-EXPORT PERCENTAGE OF PRODUCTION

Rs. 7893.31

MILLIONS

-TURNOVER 2003 - 2004

MARCH92-STARTED COMMERCIAL PRODUCTION

TPMTPMTPMTPM

1s SEIRI 2s SEITON 3s SEISO

Model Machine and Total Floor

Preparation ofJishu Hozen

Master Plan

Selectionof Model

Machine

SmallGroup

Formation

PreliminaryEducation and

Training

Initial

Cleaning

Preparation of

Fugai List

Audit

General InspectionTraining on Modules, Nut

& Bolts, Hydraulic,Transmission, Electrical

& Pneumatics etc.

Preparation ofTentative standard

for Cleaning,Lubrication and

Inspection

Horizontalapplication of

Countermeasures in

other Machines

Countermeasure

against ContaminationSources and Hard to

access Areas

AuditAudit

Standardisationof Checks

AutonomousInspection (Rev.

of stamdards)

Kaizen on hard to

inspect area.

Preparation ofJishu Hozen

Calender for

Machine

Audit Audit

JISHU-HOZEN PROCESS

STEP#1

STEP#2STEP#3STEP#4

STEP#5

STEP#0

STEP#6


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TPMTPMTPMTPMJISHU HOZEN STEP-1 (EXAMPLE)

Step - 1 : Initial Cleaning

Before

Red tags are attached to abnormalities which

can not be taken care of by Operators.

Dirty A-1 Passenger Tyre Curing Press. Cleaned A1 Passenger Tyre Curing Press.

Example:

White tags are attached to abnormalities

which can be taken care of by Operators.

After

TPMTPMTPMTPM

JISHU HOZEN STEP-2

PROCESS:

Analysis of Abnormalities

detected during initialcleaning

Rectification of Abnormalities

on Machine line, Loose Parts,

Leakages, Un-necessary items,

Missing parts etc.

Why why analysis ofcauses of forced

deterioration ( Hard

to access & Sources of

Contamination

Countermeasure Plan forHard to access areas and

Sources of Contamination

among group members

(Optr., Prodn. I/c, Maint.I/c)

Implementation of

Countermeasures and

Visual Controls

Horizontal deployment

plan for

Countermeasures


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TPMTPMTPMTPMEXAMPLE OF COUNTERMEASURE FOR CAUSE OF

FORCED DETERIORATIONMachine : TBM-M9

CountermeasurePhenemonen Analysis

Head Stock

Assy. Solenoid

Station

Solenoid hard to

Clean

Sharp edges

and

Corners

In-Built design. Machine

Requirement

Dust & Dirt on

Solenoid

Valve & regulators.

Solenoid valve station

to be covered to prevent

dust falling.

Head Stock

Assy. Solenoid

Station

Main Motor gear

box oil level and

belt drive - hard

to inspect.

Metallic cover

is there.

To protect

main motor

and belt

from

dust.

Lack of lubrication

and inspection.

Transparent cover to be

provided in place of

metallic cover for easy

inspection.

Servicer

Assembly.

Hard to

Inspect.

Less

illumination.

Poor light

arrangement.

Dust and dirt on

Servicer Assy.

Tube light to be provided

from both the sides.

Head Stock

Assembly.

FRL Unit. Hard to

Inspect.

No oil level

marking in

Lubricator.

Lack of

Lubrication.

Oil level marking to be

provided for easy

inspection.

Head Stock

Assembly.

Motor base

to clean

Cover is

fixed with

bolts.

Poor Design. Dust & Dirt. Detachable cover with

handle to be provided

for easy handling.

Where What Why 1 Why 2 Why 3 Cause Countermeasure

TPMTPMTPMTPM

EXAMPLE OF COUNTERMEASURE AGAINSTHARD TO CLEAN

BEFORE AFTER

RESULT / BENEFIT : EASY TO CLEAN. CLEANING TIME REDUCED FROM 25 MIN.PER WEEK TO 5 MIN. PER WEEK.

SUBJECT : SPLICE PRESS HOSE PIPE HARD TO CLEAN.

CLEANING OF SPLICE PRESS HOSE PIPEDIFFICULT DUE TO FIXED COVER.

HINGED COVER PROVIDED. NOWEASY TO CLEAN


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TPMTPMTPMTPM

EXAMPLE OF COUNTERMEASURE AGAINST

SOURCE OF CONTAMINATION

BEFORE AFTER

RESULT / BENEFIT : REDUCTION OF QUALITY DEFECT. (FABRIC SCRAP8 Kg. PER DAY SAVING OF Rs.800 PER DAY.

SUBJECT : SOURCE OF CONTAMINATION

FABRIC TOUCHING THE FLOOR AT BIASCUTTER DANCER ROLL AND CONTAMINATES

WITH DUST.

PLATFORM PROVIDED TO AVOID TOUCHINGOF FABRIC WITH FLOOR. CONTAMINATION

ELIMINATED.

TPMTPMTPMTPM

EXAMPLE OF VISUAL CONTROL SYSTEMS IMPLEMENTEDFOR EASY INSPECTION

OK

NOTOK

VALVE OPEN/CLOSEINDICATOR

CHILLED WATER SPRAYINDICATOR

MILL LUBRICATION OILINDICATOR

MILL TANK

LUBE

OIL

PRESSURE

INDICATOR

MILL

LUBE OIL

PRESSURE

INDICATOR


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TPMTPMTPMTPM

JISHU HOZEN STEP-3

Group Members meeting

to prepare tentative standard

for Cleaning, Lubrication,

Tightening, Inspection.

Finalisiation of Frq. (Daily, Weekly, Monthly)

Finalisation of format and colour codes.

Making the Points on

Machine for Cleaning,

Lubrication, Tightening and

Inspection.

Making lubrication points on machine,indicating type of lubrication and frq.

Putting sticker on machine to show inspectionpoints.

Marking Route near machine

Making Visual Controls

Identifying points where visual controls arerequired.

Finalisiation of colour codes to be used forOK, Not OK, Open, Close etc.

Preparation of Monitoring

Sheet for Record.

TPMTPMTPMTPM

EXAMPLES OF COLOUR CODES, SYMBOLSFINALISED FOR VISUAL CONTROL AND JISHU

HOZEN CHECKS

Green Colour for OPEN symbol.Red Colour for CLOSE symbol.

Stands for Inspection Activity.

Stands for Lubrication Activity.Stands for Cleaning Activity.

Yellow Colour for daily check sheet.

Pink Colour for Weekly check sheet.


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TPMTPMTPMTPM

EXAMPLE OF JISHU HOZEN CHECK RECORDS

CRITERIA : INSPECTION:

Route

Ref. No.

Wh en Sub -

Assembly

Where What 1 2 3 4 5 6Method

1 Daily HeadStock

Disc Brake Unit (Oil

leakage at fittings.)

No Oil Leakage

7 8

2 Dail y BottomStitcher

Bottom Stitcher

Disc.

No play and

jamming.

3 Daily BeadStitcher

Rotary encoder

coupling alignment.

No Mis-alignment.

4 Daily HeadStock

Drum Coll apsing. Abnormal Sound..

5 Daily BeadStitcher Bead tool airfittings ( Inside ), No air leakage..

6 Daily TailStock

Lubricator oil

Level.

Oil upto specified

mark.

(Signature)

TPMTPMTPMTPM

JISHU HOZEN CHECK LIST (59J TYRE BUILDING M/C.)

DAILY INSPECTION

Route

Ref. No.

When

Daily

Criteria

Inspection

Sub-Assembly

Bead Setter

Assembly

Where

Ply,Cup,Spring

& bolt (Inside)

What

Looseness

& Missing

How Time /

Responsi-

bility.

Remarks

1 5 Secs.

Operator

Equipment

Failure

Daily Inspection Bottom

Stitcher

Discs Play,Jamming

Gap

2 05 Secs.

Operator

Daily Inspection Bottom

Stitcher

Air Cylinder,

Pipes,Joints

Air

Leakage

3 15 Secs.

Operator

Daily Inspection Bead Setter

Assembly

Looseness

& Missing

4 5 Secs.

Operator EquipmentFailure

Ply,Cup,Spring

& bolt (Outside)

Daily Inspection Head Stock

Assembly

Abnormal

Sound.

5 05 Secs.

Operator EquipmentFailure

Main Motor &

Blower.)

Equipment

Failure and

Quality

Defect.

Equipment

Failure and

Quality

Defect.


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TPMTPMTPMTPM

PROCESS OF TRAINING

Objective andCurriculum

for Operators

SkillAssess-ment

Preparationof Training

Material andFacilities

TrainingImplementa-

tion

EvaluationRecording

Standard Objective Training Topic

Basic Can set, adjust, run the machine

correctly.

Correct operation (Work instruction,

Specification and Safety).

Know Machine components

and maintain them by

practicing Jishu Hozen.

Jishu Hozen Step - 1, 2 & 3 (Practice

of Cleaning, Lubrication, Tightening

and Inspection.

Advance Can check machine by

practicing Jishu Hozen.

Jishu Hozen Step-4

(GENERAL INSPECTION)

TPMTPMTPMTPMStep - 4 : GENERAL INSPECTION

Establishment of

General Inspection

Category

Preparation of

Training

Material

Training

Calender

Group

Leader

Training

Members

Training

General

Inspection

Practice

Inspection

Skill

Assessment

Revision

of Check

Sheet

Audit Next G.I.

Category


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TPMTPMTPMTPMStep - 4 : GENERAL INSPECTION

ESTABLISHMENT OF GENERAL INSPECTION CATEGORIES :

Categories

AreaBanbury 3 Roll,

4 Roll &

Dip

Extru-

ders

Bias Cutting

& Band

Building

Bead

Room

Truck

Tyre

Bldg.

Pass.

Tyre

Bldg.

Tyre

Curing

Tube

Section

Nuts & Bolts

Lubrication

Transmission

Pneumatics

Electrical

Hydraulics X X X X X X X

PREPARATION OF TRAINING MATERIAL (CATEGORY WISE) :

Nuts & Bolts

Lubrication

Transmission

Pneumatics

Electrical

Hydraulic

Categories

Training Material

OPLS MODLES /CUT SECTIONS MODLES FORG.I. ITEMS

6

4

12

15

8

12

10

12

14

23

13

6

PERSONS INVOLVED:

Training Department.

Production Incharge.

Maintenance Incharge.

TPMTPMTPMTPM

GENERAL INSPECTION AREA :- TRUCK TYRE BUILDING

EQUIPMENT:- M.H.I. TYRE BUILDING MACHINE

CATEGORY :-TRANSMISSION SYSTEM

(BEAD TOOL TRAVERSE MOVEMENT)

SPEED REDUCER

CHAIN & SPROCKET

LEAD SCREW ANDFEED NUT

BEAD TOOL

MECHANISM G.I. PARTS G.I. ITEMS

DAMAGED GEAR TEETH

GEAR OIL LEAKAGE

BEAD TOOL ANGLE. (90DEG.)

LUBRICATION OF CHAIN

LOOSENESS / TIGHTNESSOF CHAIN.

SPROCKET ALIGNMENT

SPROCKET KEY / KEYWAY /DAMAGE / WORN OUT.

LEAD SCREW LUBRICATION

LEAD SCREW & FEED NUTPLAY.

BEAD

TOOLTRAVERSEMOVEMENT

ELECTRICAL

CONTROLSYSTEM

TRANSM

ISSION

SYSTEM

MOTOR SHAFTDAMAGED / WORN OUT KEY/ KEY WAY

Examples of

TRAINING MATERIAL ON JH 4TH STEP


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TPMTPMTPMTPM

GENERAL INSPECTION AREA :- TRUCK TYRE BUILDING

EQUIPMENT:- M.H.I. TYRE BUILDING MACHINE

CATEGORY :-TRANSMISSION SYSTEM

(BEAD TOOL TRAVERSE MOVEMENT)

SPEED REDUCER

CHAIN & SPROCKET

LEAD SCREW ANDFEED NUT

BEAD TOOL

LEAD SCREW LUBRICATION

LEAD SCREW & FEED NUTPLAY.

MOTOR SHAFT

Examples of


TPMTPMTPMTPM

G.I. PART:-LEAD SCREW AND FEEDNUT

MACHINE :-M.H.I. T.B.M.

CATEGORY :-TRANSMISSION

G.I. ITEM :-LUBRICATION OF LEADSCREW.

CHECKING METHOD WHAT TO DO WHY TO CHECK

VISUALLY CHECK THAT

LEAD SCREW IS NOT

DRY OF LUBRICATION.

IF LEAD SCREW IS DRY,LUBRICATE THE LEADSCREW BY APPLYINGGREASE.

LEAD SCREW NOT LUBRICATED

LEAD SCREW AND FEED NUTWILL WEAR OUT.

BEAD TOOL WILL NOT REACHAT REQUIRED POSITION.

FEED NUT LIFE WILL BEREDUCED

QUALITY DEFECT WILL BEGENERATED

PLAY WILL DEVELOP..

MAINTENANCE COST WILLINCREASE.

Examples of



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TPMTPMTPMTPM

TOPIC:- Knowledge and Maintenan ce of Pneumatic System.

BASIC (REQUIRED LEVEL - 4)

S. NO. Question CARD NUMBER

2606 2528 2546 2533 2516 2517

K S K S K S K S K S K S

1 . C an you Ide ntify T he Pn eu mat ic

Equipment .

1 1 1 1 1 1 1 1 1 1 1 1

2. What are the check point of FRL Unit. 1 1 1 1 1 1 1 1 1 1 1 1

3 . W ha t a re t he fa il ures re la ted to Pneuma tic

Cylinders in your area

1 1 1 1 1 1 1 1

4. What is a Celebration tag. 1 1 1 1 1 1 1 1 1 1 1 1

5 . H ow to I dent if y o ut o f cal ibra ti on

Pneumatic Equipment.

1 1 1 1 1 1 1 1

Score 4 5 4 4 5 4 4 4 5 5 5 4

INSPECTION SKILL ASSESSMENT :-

1 - KNOWLEDGE AND SKILL BOTH UNSATISFACTORY.

2. -KNOWLEDGE SATISFACTORY. - 80% SCORE OF KNOWLEDGE

3. - SKILL SATISFACTORY. - 80% SCORE OF SKILL.

4 - KNOWLEDGE AND SKILL BOTH SATISFACTORY

- 80% SCORE OF BOTH KNOWLEDGE AND SKILL.

K - KNOWLEDGE S - SKILL

Each question carries one mark.T1

T3

T4T5

T6

T2

T - TOPIC

- EACH CO-CENTRIC CIRCLE LEVEL 0 TO 4.

- YEAR WISE LEVEL INDICATED BY DIFFERENT COLOURED LINES.

INDIVIDUAL RECORD OF SKILL LEVEL (SPIDER DIAGRAM)

INSPECTION SKILL ASSESSMENT

TPMTPMTPMTPMEFFECT OF STEP-4 TRAINING

NUMBER OF JH KAIZENS SUGGESTED BY OPERATOR = 133NUMBER OF JH KAIZENS SUGGESTED BY OPERATOR = 133

TO STOP SPILLAGE

LEAKAGE (OIL /

POWDER)

FOR EASY

WORKING

QUALITY WASTE

CONTROL

SAFETY OTHERS

96 105 45 13 48 26

EQUIPMENT FAILURE DUE TO NO / POOR

INSPECTION296

122

44

00

50

100

150

200

250

300

STEP#

1

STEP#

2

STEP#

3

STEP#

4

FREQUENCYPERMONTH

QUALITY DEFECT DUE TO NO / POOR

INSPECTION

24

18

8

00

5

10

15

20

25

STEP#

1

STEP#

2

STEP#

3

STEP#

4

CASES

PERMONTH


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TPMTPMTPMTPM

04 BirlaTyres

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