TPM

Abnormalities – HTA & SOC

HTA/ HTR – Hard To Access/ Hard To Reach

SOC – Source of Contamination
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Autonomous Maintenance – Step 2

Step Contents of Step Activities within the Step
0 Education - machine function & condition

1 Initial Cleaning & Inspection.

• Eliminate the sources and
2 Countermeasures to eliminate sources of contamination.
contamination and "hard to access" areas.
• Eliminate the "inaccessible"
3 Develop provisional standards for cleaning, areas.
lubrication and tightening.
• Reduce time to clean, inspect
4 General Inspection - Training &
and equipment.
Instruction of the finalized standards.

5 Autonomous Inspection • Further develop tentative

standards
6 Re-organising workplace &
Standardisation
• Develop quick kaizen approach.
7 Full Implementation of Autonomous
Management

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INACCESSABLE PLACES (HTA)

Cleaning Machine construction, Covers, Layout, footholds, Space

Construction, Covers, Layout, footholds, Instrument position

Checking
and Orientation, Operating – Range display

Position of lubricant inlet, construction, height, footholds,

Lubricating
lubricant outlets, space

Tightening Covers, Construction, Layout size, Space

Machine layout, Position of valves, Switches and levers,

Operation
Footholds

Position of pressure gauges, thermometers, flow meters,

Adjustment
moisture gauges, vacuum gauges, etc.

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CONTAMINATION SOURCES
Product Leaks, Spills, Spurts, Scattering, Overflow
Raw materials Leaks, Spills, Spurts, Scattering, Overflow

Leaking, Spills, Seeping oils, Hydraulic fluids, Fuel oils,

Lubricants
etc.

Leaking compressed air, gases, steam, vapors, exhaust

Gases
fumes, etc.

Leaking water, Hot, Cold, half finished products, Waste

Liquids
water, Leaking supply lines etc.

Flashes, cuttings, packaging materials, and non

Scrap
conforming products.

Contaminants by people & Forklifts, Infiltration through

Others
cracked walls, broken windows etc.

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STEP 2 COUNTERMEASURES AGAINST SOURCES OF

CONTAMINATION AND HARD TO DO CLRI

• COUNTERMEASURES AGAINST SOURCES OF CONTAMINATION

• MAKE APPROACH EASY FOR CLRI
• MAKE EASY TO DO CLRI
• SHORTEN CLEANING, LUBRICATING TIME
• ADOPT CONCEPTS OF LOCALIZED GUARDS
• RANKING THE PRIORITY PLACES FOR DAILY CLEANING

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Identify SOC/ HTA/ SOC

Analysis
HTA in the area Kaizen

Date of Identification
Update information on problem
Implement countermeasure

Key Activities

Machine No./ Name
Carry out Why-Why analysis for against SOC/ HTA

Select whether it is SOC or HTA identifying root cause
Update information on Format

Describe the problem or why it
Identify countermeasure/ 1 & 2 as desired
is SOC/ HTA kaizen to eliminate the repetitive
Use Format # 1 HTA/ SOC Use Format # 2 HTA/ SOC Update Format # 1 & 2 HTA/ SOC
Who?

Operators/ Supervisor/ Supervisor/ Maintenance Supervisor/ Maintenance

Circle/ Sub-circle Members Personnel/ Line In-charge/ Personnel/ Line In-charge/
Circle Members Circle Members

Reduce the CLRI time

Deliverables

Improve the 5S of the area

Improve basic condition of the machine

Improve asset life

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Examples

Easy to clean

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SOURCE OF CONTAMINATIONS

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IDEA FOR ELIMINATING FORCED DETERIORATION

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THEME: LOSS NO
LOSS STRUCTURE:
KAIZEN MACHINE: 13B5SL
KAIZEN START
TEAM:
To reduce Cleaning time 8A
Cleaning Time Reduction S.Ravindharan 15.03.2001
V.Mohan
BENCH MARK 30 Sec IDEA: P.Comarasen KAIZEN FINISH
To provide a polythene paper on the K.Patchaiappan
TARGET 5 Sec magnet to collect contaminated material 16.03.2001

PROBLEM: COUNTERMEASURE: BENEFITS :

Before After
Contaminated Contaminated
Oi material Oi
lC lC material
hu hu
te t
Cleaning the contaminated e
• Time saving / month = 533 min
material deposited in the magnet Polythene
takes more time Magnet
Paper Magnet • Timings saving / Year = 6396 min
• Effortless activity
Oil tank Oil tank

Remove magnet & No cleaning remove

cleaning by brush with Polythene paper and fix
new polythene paper
diesel then fix magnet

ANALYSIS: RESULT: HORIZONTAL DEPLOYMENT :

WHY 1 WHY 2 WHY 3 Before After
Sec
Cleaning Iron Due to Area Status
30 30 Sec
the particles magnetic
magnet not property Socket 13
takes coming BETTER 15
Hex
more out 15
time easily Special 13
from 5 Sec
magnet
0

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EXAMPLES OF LOCALISED CONTAINMENT

Before After

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Usage of
localised guards

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Eliminate cleaning by fabricating chute for

collecting disposable waste.

After

Before

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Easy to lubricate

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Countermeasures against source of contamination

Oil Localisation
Before After

Localised gaurds
The return oil flow from the feed drive gears splash and spread all around the
open space inside the machine there by getting contaminated. To avoid the
contamination, the return oil flow is channalised from the feed drive gears
directly to the lubrication tank

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DIFFICULT TO LUBRICATE  EASY TO LUBRICATE

Before After

Difficult to Lubricate the oil to Easy to Lubricate the oil to

gear box gear box

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Easy to Retighten

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Easy to Inspect

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THEME: LOSS NO.

KAIZEN MACHINE: 10B3S

KAIZEN START
LOSS STRUCTURE: TEAM: J. Sriram
To reduce Inspection time 8A Inspection Time Reduction 10.05.2001
Karunairaja
Franklin KAIZEN FINISH
BENCH MARK 30 sec / Day IDEA:
To bring the pressure gauge for K.O. system outside the Sivakumar 25.05.2001
TARGET 2 sec / Day machine for easy inspection
Ramalingam
PROBLEM: COUNTERMEASURE: BENEFITS :
Before After
Time saving = 28 sec / Day

Man hours saved per year = 15 hours

Inspection is very difficult and
taking more time in the pressure Pressure Other Benefits
gauge for K.O. system Pressure
gauge Inspection becomes easy
gauge
Inside the M/c
Outside the M/c

Difficult to Easy to
Inspect Inspect

ANALYSIS: Problem : Inspection is difficult RESULT: HORIZONTAL DEPLOYMENT :

WHY 1 WHY 2 WHY 3 Sec.

By machine 30 sec / change

Pressure gauge 30
Inspection is Better
design
kept inside the
very difficult No of Areas
and it is machine

taking 15 Identified : 5 Nos.

moretime in
pressure Implemented : 5 Nos.
2 sec / Day
gauge for 0
K.O. system Before After

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DIFFICULT TO INSPECT- EASY TO INSPECT

Before After

Difficult to Inspect the belt condition Easy to Inspect the belt condition

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DIFFICULT TO INSPECT- EASY TO INSPECT

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EASY TO INSPECT

Indication marks for nuts & bolts Indication for valve controls

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EASY TO INSPECT

Arrow sign for indicating the

Fan to indicate the function of Chiller Unit
rotating direction of Motor

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EASY TO INSPECT

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INSPECTION MADE EASY

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Thank You

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