Basic education of TPM

Chap Kobetsu-kaizen for production efficiency

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Quote From TPM Deployment program TPM encyclopedia Keyword Book

Japan Institute of Plant Maintenance)

 Kobetsu-kaizen for production efficiency

3.1 Improvement of zero failure P38

3.2 Improvement of the setup

P43

3.3 Improvement of cutting blade change loss47 3.4 Improvement of start up 3.5 Improvement of Minor stoppage 3.6 Improvement of Speed losses P50 P52 P56

3.7 Improvement of Yield lossesP58 3.8 Principle of improvement P60

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Kobetsu-Kaizen" refers to the individual improvement for further efficient production systems." It means efforts to select model equipment or a model line and to challenge the target of zero losses through project team activities according to improvement themes. Kobetsu-Kaizen" takes the form of activities through project teams composed of managerial staff members and through small workshop groups.

The procedures for the implementation of Kobetsu-Kaizen" by managerial stall members are as follows:

[1] Selection of model equipment Model equipment or a model line should be chosen. [2] Organization of a project team A team of several members should be organized, with the line manager in charge of the model equipment serving as its leader. [3] Grasping and confirmation of 16 major losses [4] Decision on the theme and preparation of a promotion program [5] Kobetsu-Kaizen" project activities For these activities, failure analysis methods and IE methods should be utilized. For chronic losses, PM analysis should be applied. [6] Standardization and horizontal evolution should be completed for enhancement of OEE
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 Improvement of zero failure

Common challenges related to failure
(1) No interest production Section The worker is not anything other than work For safety reasons, worker does not touch the equipment There is no provision Workers just do not know how to Maintenance If Teach Maintenance to Wokers ,They can . (2) Failure analysis is poor They have not drawn broken parts They dose not have to disassemble the defective part They only exchange parts No relapse prevention

Maintenance personnel does not understand the function of the parts They does not understand Why-Why analysis
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(3) Maintenance system is incomplete Judgment standard ,method of inspection , inspection points is incomplete Defective Maintenance schedule Record system of failure (4) Predictive maintenance is poor Periodically measuring equipment to determine the abnormality Precision diagnosis Measure vibration, current load, timing, operating time, sound, etc and then understand the change point

If there is no data management can not be right!

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 Thinking reduction of failure

(1) Classification of failure
failure Classified simple and complex then Give priority to simple failure Method of stratified Mode causes / line/Occurrence location (2) Failure analysis Stress on the equipment Electric or mechanical stress, temperature, humidity, dust, vibration,

Intensity <Stress Failure occurrence

Cause failure
deficiencies basic conditions Do not keep the terms and conditions Degraded without Restore lowering skill Lack of design

To educate and Change the way of thinking and Change their behavior
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1 Four phases to achieve zero failures

Four phases to achieve zero failures Improvement of design shortcomings (corrective maintenance),prevention of random failure A short-term and simultaneous implementation occurrences due to operation or repair errors, and restoration by fixing external appearance of the five measures for zero breakdowns is unlikely to progress smoothly. It is more effective deterioration. to divide enforcement of the measures into four - Phase 3: To periodically repair deterioration to phases and implement them one by one under a restore original conditions. plan. Through these steps, steady approach to Regular deterioration repair to restore the zero failures will become possible. original conditions The four phases and principal themes of periodic maintenance: TBM), and grasping of individual themes are as follows: abnormal symptoms of internal deterioration based on the ve senses. ~ Phase 1: To reduce dispersion of MTBF - Phase 4: To foresee the service life. mean time between failures. Prediction of the service life based on condition Repair of previous uncovered but unamended diagnosis degradation to restore the original conditions, techniques (predictive maintenance: CBM), and preparation of basic conditions, and technological prevention of artificial machine deterioration analysis of catastrophic failures. through observance of usage conditions. - Phase 2: To extend inherent service life.
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1 Five measures to achieve zero failures

Failures represent only the tip of the iceberg, so to speak. The leaving of latent defects below the water surface" causes failures. Methods for uncovering such latent defects and preventing failures are the "five measures to achieve zero failures, "and they are as follows: [1] Put basic conditions in place: Keeping of basic conditions for equipment, i.e., enforcement of cleaning,oiling, and retightening (of bolts and nuts). l2] Abide by operational conditions: Observance of the specified operational conditions of the equipment, such as pressure, temperature, speed, and flow rate. [3] Restore original functions by fixing deterioration: The prevention of forced deterioration of quipment is possible by preparing basic conditions and abiding by usage conditions. Even so,natural deterioration, such as wear, corrosion, fatigue, and declining insulation, inevitably occurs. Therefore, such deterioration should not be left unattended but corrected to restore the original conditions. l4] Improve design weaknesses: Only repeating correction of deterioration cannot lead to progress. To begin with, deterioration may be accelerated due to material selection errors or structural defects during design stage. Such design shortcomings must be rectified (this is corrective maintenance). ' l5] "Improve skills:
Ask to the machine

cleaning,oiling, and retightening is Important

 Improvement of the setup

This is one of the seven major losses that impede equipment operations and Adjustment means the following: refers to the time lost from the [1] Measures to be taken to seek the termination of the production of a optimum solutions or values to attain present item until the good-quality some purpose; for instance, the manufacturing of the next item procedures to put quality within subsequent to setup and adjustment. designed values The setup here means a series of work: W hat is achi ev ed t hro u gh t he removal of jigs/tools upon the completion [ 2] r e petition of trial and errors of the on-going production, clearing up, cleaning; preparation,attachment, adjustment, and measurement of jigs/tools required for the next item and manufacturing of non-defective products. There remain many issues to be addressed to shorten the time spent on internal setup (setup during machine stoppage) and external setup (setup without machine stoppage) based on IE approach.

Understand the setup, to quantify

 Improvement of the setup

(1) Organize and tidy Management position of tooling Do not search, do not move positioning centering the correct dimensions timing (2) Clarification External setup and Inter balance setup Study Elimination of work-Cause of the adjustment Review of work procedures cumulative error shortage standardization (3)Study External setup to Inter setup shortage rigidity Preset(Pre-assembled) Sharing of jig and Exchange one-touch Analysis of adjustment Changes the adjustment to External setup Study the one-touch setup Using the auxiliary jigThe elimination of adjustment

(4) Study procedures of Inter setup Study on method of fixation Screw fixing Hydraulic One worker Two worker Time savings (5) The elimination of adjustment The purpose of the adjustment

Study eliminating waste of External setup and Inter setup

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Viewpoint Improvement of setup

5S, preset, standardization, into fixture, no adjustment

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One-touch attachment and Analysis of adjustment

The elimination of adjustment One-touch attachment

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Improvement of cutting blade change loss

Problem of cutting blade

The life of the cutting tool
Shape and material of the cutting tool

Cutting conditions (cutting speed)

Material, hardness

requirements of Quality product

(Dimensional accuracy, surface roughness)

Rigidity of the equipment

Look the cutting edge

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Exchange conditions Reason: Unclear Exchange standards Failure occurs, Exchange without permission Inhibiting unattended operation Reason: varies Quality Short-cutting tool life Occurs Minor Stoppage Reduction of cutting tools cost Storing the old chip No management objectives of cost cutting tool Many kinds of cutting tool Management chip is loose No historical record use of a chip No Management abrasion of the chip (Can be use but exchange can not use but No exchange)

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Detection parameters of the cutting tool life

Quantify sound, vibration, AE, resistance, current, heat 15

3.4 Improvement of start up

Start-up losses denotes the time losses and volume losses (from defects and remark) until product quality stabilizes to manufacture non-defective products even in accordance with the specified cycle time without mechanic troubles, such as minor stoppages, small troubles, and breakage of cutting blades, during [1] start-up after periodic overhaul [shutdown maintenance] [2] start-up after downtime (long-term line stoppage) [3] start-up after holidays [4] start-up after the lunch break. At a machining shop dimension dispersions are likely to occur during the morning setup, causing frequent adjustments, rework due to failure to adjustment, and breakdown of cutting blades. To prevent these, warm-up and idling operations are conducted early in the morning. The target of start-up losses is minimization.

Understanding the thermal displacement!!

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3.4.2 Improvement Way of start up

(1) measure
Measuring temperature of the table, Main shaft, etc to stabilize.

(2) Study Material

Consult the manufacturer the material to minimize thermal displacement

(3) Cooling the generator

Cool heat by Cooling fan

(4) Automatic correction

Automatically adjusts to predict beforehand the amount of displacement

Study Cause,Thermal displacement curve,Time to settle

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3.5 Improvement of Minor stoppage losses

[1] In case temporary functional stoppage ensues. because of a quality defect to cause a temporary stoppage.

[2] in case the recovery of functions is These are the conditions in which the made by simple fixing machine will revert to normal (elimination of abnormal workoperation, if the stuck workpiece and/or resetting) piece is removed, or resetting is carried out. Therefore, they are fundamentally different from [3] ln case parts exchange or repair machine failures. are not required. To reduce minor stoppages, it is important to in detail analyze phenomena [or slight defects] and to thoroughly eliminate Unlike failures, minor stoppage/idling slight defects. losses represent a status in which the machine is subjected to either stoppage or idling due to temporary troubles; for instance, when a work-piece is clogged in the chute, idling occurs ; or when a sensor activated [4] Recovery time lasts from 2 or 3 seconds less than 5 minutes.
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Observation, analysis, stratified to investigate at the site

3.5.2 Improvement Way of Minor stoppage losses

(1) Phenomenon analysis and motion analysis of workpiece: Video recording the phenomenon of Minor stoppage , Viewpoint is movement posture, angle, float, vibration

(2) Remediation of the defect: Contact surface of the workpiece is key point Improve the small defects of parts and jigs
Compliance with the basic maintenance Cleaning, refueling, retightening Compliance with of the basic tasks Correct operation, setup, adjustment Study on optimum condition Studied the optimization of processing conditions of Parts Study Weakness: Studied the problem of the design of equipmentparts,jigs
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Understand the movement of the workpiece by video shoot

Classification of phenomenon and Classification of causes

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 Improvement of Speed losses

One of the seven major losses impeding improvement based on the current efficiency improvement of equipment. These technological level. There is a speed loss of losses incurred by slow machine speed are 10 seconds in this case. defined as follows: Aiming at speed increase would contribute to [1] Losses due to the difference between the clarification of problems and actual speed and the design upgrading of technological levels. Therefore, speed (or reference speed for each product the target should be to make item) nit the difference between the design speed [2] Losses resulting from lower design speed and the actual speed. compared to the present technological level or desirable speed (or mission speed) As an example of the former case, the cycle time is 60 seconds as reference but the actual operation cycle time is 65 seconds. There is a speed loss of 5 seconds. As an example of the latter case, the cycle time is set at 60 seconds but it could be reduced to 50 seconds through

Into the data to understand the current status of equipment!

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 How to improve the speed loses

Understand the cause
To speed up For the experiment.
Changes in Cp New bad item The life of the cutting tool Number of occurrences of Minor Stoppage Percentage occurrence of defective Examine the aggravating factors measures ahead

Check the validity of the action

Reduction of air cut time Reduction of idle time Reduction of operating time Reduction of working hours by two people work Make improvement on equipment mechanism, component structure, timing, the cycle diagram.

Study Air cut time,Idle time,Operating time,Two person work

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 Improvement of Yield losses

This refers to the volume losses resulting from in the case of aluminum casting, this refers to differences between raw material weight the and product weight, or between raw losses representing runner weight and blur materials input and product weight. Weight. The former represents material losses that can result from leaving too much iron cast for fear of casting shortcomings (such as sand inclusion) or from forging too thick so that it may be sufficient enough to obtain mold precision in the shaping process. As a result of these, cutting time can be lengthened, or the service life of cutting blades shortened. The latter represents the difference between whitewash weight, gate weight, generated burr volume and the product weight. in other words, the losses in this category result from increased burr generation due to molding precision insufficiency.

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 How to to reduce chronic defects

Immobilization of variable factors
factors?:Impact phenomena logically
CauseWhich have proved to have influenced the phenomenon

Restore ,For Immobilizing the "Variation factor"!

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 Principle of improvement

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Please read the next chapter at Sideshare

4Step of Jishu-Hozen Activities

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