2015 No. 7 A Practical Christianity - ShaftesburyCofE.org.uk
AM Practical No.4
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![Page 1: AM Practical No.4](https://reader033.fdocuments.net/reader033/viewer/2022061304/550282d14a795971028b51fd/html5/thumbnails/1.jpg)
INTERNATIONAL COLLEGE OF AUTOMOTIVEDIPLOMA IN AUTOMOTIVE MANAGEMENT SYSTEM
GROUP PRACTICAL
GROUP NUMBER :GROUP 4
GROUP MEMBERS NAME : 1. Mr. Amir Bin Haridan ( EDMS -1004 - 00000027 ) 2. Mr. Mohd Azhar Bin Mohd Yusof ( EDMS -1003 - 00000017 )
3. Mr. Mohd Shaid Bin Ghazali ( EDMS -1003 - 00000008 ) 4. Mr. Muhammad Shamsudin Bin Jahaya ( EDMS -1004 - 00000030 )
5. Mr. Muhammad Faizal Bin Satar ( EDMS -1003 - 00000010 )
MODULE : MMS 1063 - AUTONOMOUS MAINTENANCE SEMESTER : 3
TITLE : CORRECTIVE ACTION AND KAIZEN REPORT
GROUP PRACT. NO : 4
LECTURE : Mr. Azam Bin Musa
MARKS : __________________________
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1. Introduction Fuguai detection Source and contamination Difficult Area.
2. Fuguai Detection List3. Source and Contamination List4. Difficult Area list5. Problem Definition6. Containment Action7. Root Cause Analysis8. Why-Why Analysis9. Corrective Action
Corrective Action 1 ~ 4
10. Verification11. Preventive Action12. KAIZEN13. Conclusion
Contents
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Automation become popular among Japanese manufacturers. Automation eliminates drudgery manual labor, improves the quality and reduces cost.
The uniqueness of AM is that the maintenance is carried by the Production department. The success of TPM depends on upon the success of the Autonomous Maintenance Program.
Introduction
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Fuguai ListNo Location Photo Fuguai Tag Tag
TypeOptional Action P.I.C Date
1 Inside Front Dusty at area and light not function Blue Tag
Clean the dusty and check light to make sure the function ok
Prepare cleaning checklist and change new bulb
Shaid
11/5/2011
2 Front Side The door not tightly closed and a lot chip in this area. Red Tag
Tightly all nut at the door and cleaning all chip
Prepare fastener checklist
Shamsudin
9/5/2011
3 Right Side The door not tightly closed and there area lot at chip. Red Tag
Tightly all nut at the door and cleaning all the chip
Prepare fastener checklist
Faizal
7/5/2011
4 Inside Front Cover crack source a lot chip in this area. Red Tag
Change new transparent cover and cleaning all chip
Change new transparent cover
Azhar
10/5/2011
5 Back Side There are a lot chip and oil in this area. Blue Tag
Cleaning all chip and check the oil hose if licking change the hose
To provide Maintenance Checklist schedule
Amir
8/5/2011
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Fuguai ListNo
Location
Photo Fuguai Tag Tag
TypeOptional Action P.I.C Date
6Back Side
There are a lot chip in this area.
Blue Tag
Wipe and clear all chip
To Update cleaning Checklist
Shaid
11/5/2011
7Back Side
there are a lot of dust, chip and oil in this area.
Blue Tag
Use cotton rag, water and soap to clean dust and oil.
To Update cleaning Checklist
Samsudin
9/5/2011
8Front Side
Cover transparent not clear.
Blue Tag
Change the new cover transparent.
To Change New Transparent cover Faizal
7/5/2011
9Front side
Panel switch button a lot dust and oil.
Blue Tag
Use cotton rag to clean dust and oil.
Provide Cleaning Checklist
Azhar
10/5/2011
10Right Side
There are a lot chip ,dust and oil in this area.
Blue Tag
Use cotton rag,water,soap and air gun to clean and clear dust, chip and oil.
Provide Cleaning Checklist
Amir
8/5/2011
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Source of contaminantsNo Location Photo
Source Of Contaminants
Tag Type
Optional Action P.I.C Date
1 Front Side
Cover broken not protect from dust, oil and chip.
Red Tag
Change new
cover
To Change new
transparent cover Shaid
11/5/2011
2 Front Side
No cover to protect from dust, chip and oil.
Blue tag
Provide transparent cover
To Install new
transparent cover Shamsudin
9/5/2011
3 Left SideCover
transparent left side not clear.
Blue Tag
Change new
cover
To Change new
transparent cover Faizal
7/5/2011
4 Front SideCover transparent not clear.
Blue Tag
Wipe transparent cover
To Prepare cleaning checklist
Azhar
10/5/2011
5 Back sideWiring not
proper.Red Tag
Make proper wiring
Prepare S.O.P
Amir
8/5/2011
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Difficult areasNo Location Photo Difficult
AreasTag
Type Optional Action P.I.C Date
1 Inside Left
Narrow place to be clean.
Blue tag
Take time to
cleaning and
careful
Prepare Cleaning
S.O.PAzhar
11/5/2011
2Inside Front
Narrow place to be clean.
Blue Tag
Take time to
cleaning and
careful
Prepare Cleaning
S.O.P
Shaid
9/5/2011
3 Inside Left
Sensitive area and narrow place to be clean.
Red Tag
Take time to
cleaning and
careful
Prepare Cleaning
S.O.P
Shamsudin
7/5/2011
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CNC MACHINE
HYDRAULIC PUMP ( OIL SEAL LEAKING)
PROBLEM
Machine Problem
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MC 1 MC 2
LOCATIONPROBLEM
STATEMENTAREA VISUAL
1.Operator was found oil leaking during production at shop floor.
2.Problem happens after 4 hours machine run the production
Problem Definition
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1. Stop Production
2. Off machine
3. Close the main source of oil pump hydraulic to avoid too much oil spill
4. Wipe the leaking oil
5. Inform the leader
PUMP HYDRAULICSTEPS
Containment Action
PIC
AMIR HARIDAN
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Ishikawa diagram
VALVE PLUGGED UP
OIL SEAL LEAKING
OPERATOR NOT ALERT DURING RUN
THE PRODUCTION
LACK OF SKILL
MAN
METHOD
MACHINE
MATERIAL
SPARE PART PROBLEM
MAINTENANCE CHECK SHEET NOT
PROPER
HYDRAULIC PUMP
LEAKING
PARAMETER PRESSURE NOT FUNCTION
WRONG PARAMETER OIL PRESSURE
Root Cause Analysis
LEGENDTRUE PROBLEMFALSE PROBLEM
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causes why1 why2 why3 why4 why5
Operator not alert during
run the production
Knowledge about machine
poorno experience New worker No training
Oil sealleaking
Oil seal insulator torn Old oil seal
No maintenance
No schedule No PIC
wrong parameter air
pressure
Operator not check before
run the machine
No standard manual for air
pressure Not provided
by engineering
spare part problem Quality poor
Not followed specification
5 WHY analysis
Why-Why Analysis
PIC: SHAIDDATE: 11/5/2011
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CAUSES CORRECTIVE ACTION
operator not alert during run the production
1. Provide on job training to all new employee2. Provide training3. Remain to all operator to ensure machine in good
condition before run the machine(morning assembly)
Oil seal leaking 1. Provide maintenance check sheet and schedule2. Put PIC
wrong parameter air pressure 1. Provide automatic air pressure2. Always check the air pressure before run the production
spare part problem 1. Refer to supplier why quality of part poor2. Buy the good quality spare parts
Corrective Action
PIC: FAIZALDATE: 11/5/2011
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ACTION SAMPLE TRAINING CHECKSHEET
1. provide on job training to all new employee
2. provide training3. remain to all operator to ensure machine
in good condition before run the machine(morning assembly)
Corrective Action 1
AZHAR
SUDIN
BOB
SHAID
PIC: AZHARDATE: 11/5/2011
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ACTION SAMPLE MAINTENANCE CHECKSHEET
1. Provide maintenance check sheet and schedule
2. Put PIC
Corrective Action 2
PIC: SHAIDDATE: 11/5/2011
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ACTION SAMPLE AIR PRESSURE MANUAL
1. Provide automatic air pressure
2. Always check the air pressure before run the production
Corrective Action 3
PIC: FAIZALDATE: 11/5/2011
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ACTION SAMPLE INSPECTION SHEET
1. Refer to supplier why quality of part poor.
2. Buy the good quality spare parts.
Corrective Action 4
PIC: AZHARDATE: 11/5/2011
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Verification
IMPROVEMENT REPORTAction: Change new oil
sealVerify by: Abu Bin AliDate:11th May 2011Sign:………………………….Approve by: Ali Bin BakarSign:………………………….(Head of Maintenance)
FORM PICTURE
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PROBLEM PREVENTIVE ACTION
Operator not alert during run the production
1. Training to all employee every week2. Monitoring operator knowledge and skills
(skill chart)
Oil seal leaking1. Provide maintenance thrice a year2. Monitoring every time machine
performance
Wrong parameter air pressure1. Monitoring the air pressure during run the
production
Spare part problem
1. Do the inspection for incoming parts from supplier
2. Buy parts high quality
Preventive Action
PIC: SHAMSUDINDATE: 11/5/2011
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KAIZEN
HMS DIV.HEAD DEPT. HEAD SECTION HEAD PREP. BY
En.Shukri En.Azalan En.Azam En.Nadzrul Shaid
PROPOSED BY Mohd Shaid Bin Ghazali LOCATION IMPLEMENTATION Distribution box
KAIZEN NAME Application Conduits wire and cable tie DATE IMPLEMENTATION 15 May 2011
PROBLEM COUNTERMEASURE RESULT
Hydraulic pipe leaking due to oil seal broken.
Change the heavy duty oil seal.
No oil leaking and easy to cleaning.
BEFORE AFTER
GEMBA KAIZEN REPORT
REPORT NO: EDMS-1003-008/11
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HMS DIV.HEAD DEPT. HEADSECTION
HEADPREP. BY
En.Shukri En.Azalan En.Azam En.Nadzrul Shaid
PROPOSED BY Mohd Shaid Bin Ghazali LOCATION IMPLEMENTATION Motor bending machine
KAIZEN NAME Provided transparent cover DATE IMPLEMENTATION 5 April 2011
PROBLEM COUNTERMEASURE RESULT
Dust covers the hydraulic motor.
Fabricate new transparent cover to protect from Dust.
No more cleaning activity at cover area and easy to inspection.
BEFORE AFTER
GEMBA KAIZEN REPORT
REPORT NO:EDMS-1003-009/11
With Transparent cover
Without Transparent cover
KAIZEN
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Every step in Autonomous Maintenance is very important to ensure all activities to smooth running.
The most important to identify of a basic AM is a fuguai, source contamination, difficult areas and how people involve in all activities.
When AM activities are done according to the schedule, the machines life will long lasting, high quality, and will improve the production furthermore reduce the cost.
Conclusion