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Jishu
Hozen Pillar 7 Steps
Prepared by
Lakshmi Narayanan
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Development of JH
for equipment
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| Steps |
Category |
Activities |
Target |
Guidance
and promotion |
| Equipment |
Operator |
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| 1 |
Initial
Cleaning and inspection |
Complete
elimination of dust and dirt, especially on the equipment |
Prevention
of forced deterioration caused by dust or dirt |
Formation
of mind fungai to the equipment through touching and handling
equipment |
Pointing
out& guidance of the priority clean-up areas. |
| Performance
of lubrication & retightening, discovery & rectification of
slight equipment defects |
Discovery
and rectification of latent defects through clean-up |
Cultivation
of the ability to identify equipment "fungai" |
Instructions
in the importance of clean-up (education) |
| Removal
of unnecessary things, orderliness and tidiness of tools and jigs(1S
& 2S) |
Discovery
of areas where clean-up is difficult |
Recognition
of the importance of clean-up |
Preparation
of diagnosis sheets |
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Removal
of unnecessary things around the equipment |
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Responsibilities
in the operation and implementation of activities |
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Rationalization
of lubrication |
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| 2 |
Counter
measures for the causes of forced deterioration and improving to
hard-to access areas |
Implementation
of countermeasures against such sources as dust & dirt &
prevention of spilling leakages. |
Making
the equipment cleaning and inspection easy through improvement of
the sources of dust and dirt and areas where inspection and cleaning
are difficult |
KAIZEN
of nearby items to practice and to master the application of the
KAIZEN method and concept |
Concept
and practice of equipment Kaizen |
| Implementation
of countermeasures against areas where cleaning and inspection are
difficult (operation improvement for shortening the time needed for
cleaning and service) |
Improvement
of maintainability |
Enjoy
the KAIZEN activities (Pleasure of hand-made) |
How
to prepare the criteria or standards |
| Ranking
the priority places for daily inspection |
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Implementation
of visual control and instruction on device development |
| Confirmed
of KAIZEN and its effect |
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| 3 |
Preparation
of tentative JH standards |
Preparation
of action criteria to allow positive clean-up, lubrication and
retightening maintenance within shortest time |
Keeping
the 3 basic elements of equipment maintenance clean-up, lubrication
& retightening |
Self-decision
of criteria and its strict observance |
Preparation
of standards for technologies and techniques |
| Kaizen
of inspection method and visual control |
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Each
worker learns to be aware of individual roles. |
Clarification
of procedures to study what the equipment must be |
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| 4 |
General
inspection |
Mastering
inspection skill, utilizing inspection manuals |
Restoration
of deterioration by exterior general inspection of equipment and
reliability improvement |
Acquaintance
of inspection skill |
Preparation
of training text for general inspection |
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Discovery
and restoration of general inspection |
KAIZEN
of areas where remedial action and normal inspection are difficult |
Understanding
the equipment functions and mechanism |
Planning
of education & training schedule |
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Preparation
of autonomous inspection standards |
Making
inspection efficient |
Mastering
how to put together data and how to use it |
Execution
of leader training |
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Activation
through KAIZEN activities |
Follow-up
of education and training |
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Learning
the importance of education on communication |
Preparation
of general inspection manual and check sheets |
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| 5 |
Autonomous
inspection |
Review
clean-up, lubrication and general inspection criteria and integrate
them into comprehensive criteria to contribute to efficiency
activities |
Positively
keeping the restoration from deterioration by means of general
inspection |
Maintenance
of one's own equipment by oneself |
Teaching
how to precisely analyze the data |
| Preparation
and implementation of autonomous inspection check sheets |
KAIZEN
of equipment which has good operability |
Self-decision
and strict observance |
Effective
equipment management & maintenance |
| improvements
of visual control and operability |
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JH
is learning what the ideal |
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| 6 |
Standardization |
Picking
the items to be managed |
KAIZEN
of equipment reliability, maintainability and operability |
Improvement
of management technology |
Technical
guidance to promote standardization |
| Standardization
of management items and systematization of maintenance management |
Review
and Kaizen of equipment environment and layout |
Expansion
of JH management scope |
Revision
of management standards
and thoroughness of management |
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Thoroughness
of visual control |
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| 7 |
Autonomous
Management |
Development
of company policy/goals and quantitative analysis of Kaizen
activities |
KAIZEN
of equipment reliability, maintainability and operability through
equipment KAIZEN by applying various data analysis |
Enhancement
of goal consciousness, including maintenance cost |
Technical
assistance for equipment KAIZEN |
| Positive
implementation of MTBF analysis and recording (recording failure by
visual control) and equipment KAIZEN |
Keeping
overall equipment efficiency at its best |
Acquirement
of skill to perform minor repair by oneself |
Standardization
of improved items |
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Acquisition
of data recording and analyzing technique and KAIZEN technology |
Education
and training in repair skills |
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