Professional Documents
Culture Documents
PILLAR
Hinshitsu Hozen
or
Quality Maintenance
1
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TPM Club India Quality Maintenance Pillar
“Hinshitsu-Hozen”
What is “Hinshitsu-Hozen?
* Condition setting :
Set conditions for zero defects aimed at equipment and processes that do
not produce quality defects.
* Daily and periodical inspections :
Inspect and measure conditions in time series.
* Quality preventive maintenance :
Prevent quality defects by maintaining measured values within the standard
* Trend control and predictive maintenance :
Predict possibilities of quality defects occurring by observing trends of
measured values.
* Prior countermeasures:
Take measures beforehand
© JIPM, 1994 2
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TPM Club India Quality Maintenance Pillar
Quality Assurance
Jishu-Hozen activities
+
+
Equipment and Material
Design check Skill Education and Training
environment management Management
Individual PM Analysis
Improvement Setting of Conditions
Basic Thinking of Improvement (Technical Aspect) Decide
Restoration
properly
Pursuit of the optimal Condition
Elimination of Minor Defects
Adjustments
Clarification of Skill
Autonomous Condition Control (Control
Maintenance 7 Steps of Autonomous Maintenance Aspect) Observe precisely
• Daily Inspection
• Proper Operation
Preventive
Application of Equipment Diagnosing Technology
Maintenance
Feedback
MP Design
Realization of Zero-Defect
Education and
Training
Fostering of personnel who thoroughly understand
the equipment
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• 3M Analysis
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Defects classification
A - Type defect B - Type defect C - Type defect
OK OK NOT OK
NOT OK NOT OK
LSL OK USL OK
LSL USL OK
LSL USL
OK
NOT OK
Action taken by
operator
LSL OK USL
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Confederation of Indian Industry
KAIZEN - SHEET Unit Sub Comm Year SL. No.
To eliminate process scrap due to Damage of M133551 Crank shaft Team MembersM . Karthikeyan
Problem/Present Status : Before improvement:
Result / Benefit : Scrap due to wrong
4
loading
3
Rejection Qty
8
3
Rejection Qty
6
6
2
4
4
3
1
2
0
0
Kaizen
Analysis : After improvement: type Reversible Ir-reversible
Component damage – Induction hardng If reversible updated in
Operation Standard / QCPC
Why
JH Check Sheet
PM Check Sheet
Inductor hitting the component
Eqpt / fixture Drawing
Why POKA YOKE Scope & plan for Horizontal Deployment
Component loaded in the wrong direction SLNo. M/cNo. Target date Resp. Status
Why
1 EMA Mar’01 MK Compld.
Possibility of wrong loading
Root Cause: Possibility of Wrong Loading
Poka Yoke type & Function Shut Down
Idea : Prevent Possibility of Wrong Loading
Prevention Control
Counter measure : Provide POKA YOKE Detection Warning
KAIZEN - SHEET Unit Sub Comm Year SL. No.
3 3
Rejn Qty
Rejn Qty
2 2 2 2
2 2
1 1
1 1
0 0
0 0
June July Aug Sep June July Aug Sep Oct Nov
Qty
2 2
2
Qty
1 1
0 0 0 0 0
0
pr
ar
b
ay
l
Ju
Jan'00 Feb Mar
'0
Fe
Ju
M
M
n
Ja
Kaizen
Analysis : After improvement: Not able to type Reversible Ir-reversible
Damage in body load
If reversible updated in
Operation Standard / QCPC
Why ? JH Check Sheet
Wrong loading of component Poka Yoke PM Check Sheet
Eqpt / fixture Drawing
Why ? pin
Scope & plan for Horizontal Deployment
Fixture accepting wrong loading
SLNo. M/cNo. Target date Resp. Status
Why ?
No stopper arrangement to 1 086303 Aug’00 BDN completed
avoid wrong loading
Root Cause: No stopper arrangement to avoid wrong loading
Poka Yoke type & Function Shut Down
Idea : Provide stopper to avoid wrong
Prevention Control
loading
Counter measure : Provide Poka yoke pin Detection Warning
TPM Club India Quality Maintenance Pillar
OK
NOT OK
No action by
operator
LSL OK USL
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Confederation of Indian Industry
KAIZEN - SHEET Unit Sub Comm Year SL. No.
3
3 4
2 Rough boring 3
2
1 1 2
1
Finish boring 1
0 0
0 0 0 0 0
0
Mar Apr May May June July
Back facing Aug Sep Oct Nov
Rough finish on
Kaizen
Analysis : bore
Why ? After improvement:
Process sequence type Reversible Ir-reversible
Entrapment of Burr on bore during Facing , OD Turning & grooving
If reversible updated in
finish boring operation . Operation Standard / QCPC
JH Check Sheet
Why ?
PM Check Sheet
Burr generated during Rough boring Rough boring Eqpt / fixture Drawing
operation not fully flushed out
Scope & plan for Horizontal Deployment
Why ?
Back facing SLNo. M/cNo. Target date Resp. Status
Finish boring operation done immediately
after rough boring operation . . 01 032304 Nov ‘ 99 NKN Completed
Finish boring
Process sequence
Root Cause: Presence of burr during boring operation
Poka Yoke type & Function Shut Down
Idea : To eliminate burr presence
Prevention Control
Counter measure : Change process sequence Detection Warning
KAIZEN - SHEET Unit Sub Comm Year SL. No.
Rejection Qty
4 4
3
Rejection Qty
3 2
2 1
1
1 0 0
0
0 Mar'00 Apr'00
Dec'99 Jan'00 Feb'00
Kaizen
Analysis : After improvement: type Reversible Ir-reversible
High rejection in 120802 If reversible updated in
Why Operation Standard / QCPC
JH Check Sheet
Tool digging PM Check Sheet
Why Eqpt / fixture Drawing
Excess Runout in the component Scope & plan for Horizontal Deployment
Why SLNo. M/cNo. Target date Resp. Status
Component not located properly
Why 1 120801 Jul’00 MK Completed
No tailstock clamping
Root Cause: Tailstock not clamping
Poka Yoke type & Function Shut Down
Idea : Eliminate tailstock not clamping
Prevention Control
Counter measure : Provide limit switch Detection Warning
TPM Club India Quality Maintenance Pillar
Action taken by
OK operator
LSL OK USL
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KAIZEN - SHEET Unit Sub Comm Year SL. No.
Rejection Qty
to 6
6
0
0
Kaizen
Analysis : After improvement: type Reversible Ir-reversible
Oil port Spot face height undersize
Setting Master If reversible updated in
Why? Operation Standard / QCPC
More material removed on face JH Check Sheet
PM Check Sheet
Why?
Eqpt / fixture Drawing
Tool length set excess 12.5
Scope & plan for Horizontal Deployment
Why?
SLNo. M/cNo. Target date Resp. Status
No Setting facility
How? 1 086301 Jun’01 MK Compl.
Provide Setting facility
30 8 1 4
Big dial
20
2
7 6
5
20 0
10 0 0
0 0 Small dial
10
Nov Dec Jan’01Feb’01Mar’01
Nov Dec Jan’01 Feb Month
Kaizen
Analysis : After improvement: one rotational dial gauge type Reversible Ir-reversible
If reversible updated in
Dia 140.9 / 105.10 Bore over size Operation Standard / QCPC
3 4
5
2 6
JH Check Sheet
1
Wrong Setting by operator
7
PM Check Sheet
Eqpt / fixture Drawing
Scope & plan for Horizontal Deployment
Wrong reading of the dial
SLNo. M/cNo. Target date Resp. Status
If standard values are set for individual inspection items, and equipment
If they cannot, the cause is either that "there are omission in inspection items"
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TPM Club India Quality Maintenance Pillar
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TPM Club India Quality Maintenance Pillar
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TPM Club India Quality Maintenance Pillar
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TPM Club India Quality Maintenance Pillar
4 Check each input whether Standard exists or not. If not then make a standard.
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QM Master plan
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TPM MASTER PLAN QM SUB COMMITTEE
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MASTERPLANFORQUALITYMAINTENANCEACTIVITIES.
Activity Palnned Actual Plant. A Actual line A Actual line B Actual Slitting
Year 2004-2005 2005-2006 2006-2007 2007-2008
QM-STEPS Details of activity Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3
1. Preparationof *Check qualitycharacteristics.
QAMatrix: *Investigatedefect modes and
subprocess wheredefect occures.
*Assess seriousness of defect mode.
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TPM Club India Quality Maintenance Pillar
3M analysis
product.
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2 Soft 1) Even spreading of mix 1) Curing pressure as per 1) Inclined Plate Flow value
in the moulds. the specification. of the powder resin as per
specification.
2) Cleaning of mould edges 2) Temperature in the curing
after the application of Liquid mould as per specification. 2) Curetime of the resin as
emulsion solution in the per specification.
moulds.
3) Variation in the bulk
density of the mix.
5 Flash 1) Cleaning of flashes in the 1) Clearance between the 1) Inclined Plate Flow of the
Dent edges of the box after mould and the spacers powder resin as per the
unloading the lining from the specification
curing moulds. 2) Curing pressure as per
the specification.
6 Thickness 1) Weighment of mix as per 1) Curing pressure as per 1) Bulk density of the mix as
Unclear the specification the specification per specification.
How to
3M Condition Required value Responsibility Frequency What to do
check
No.1 product weight 0.75 - 0.80 Gms. Weighment Prodn.sup Hourly
Material(LATEX)
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Execution of PM analysis
for exposure and handling of malfunctions
Air Entrapment Force applied by 01) Thrust 1.1) Air Leakage 1.1.1)Air Leakage from joints of Bellow.
between Nylon Stitcher on exerted by inside bellow. 1.1.2) Degraded Beloow
Carcass surface (A) Rubber Tread Stitcher Disc is
and Rubber Tread Surface is less less. 1.2) Required Air 1.2.1) Air leakage from pipe joints.
bottom surface(B). than the resistance does not reach in 1.2.2) Leakage from Pipe
given by bellow from air Hose.
Rubber Tread.
1.3) Stitcher disc 1.3.1) Lever Bush Wear Out
oblique transfer less 1.3.2) Pin Bush Wear Out
thrust
1.3.3) Housing Bush Wear Out
1.3.4) Feed Nut Wear Out
1.3.5) Sprocket teeth Damage
1.3.6) Loose Coupling of Sprocket
EVALUATION
EVALUATION
06) -Worm gear thread Dimension Check ID-76.2± 0.2mm. ID-75mm. Not ok, to be Changed OK
WormGear damage (Vernier) changed
Depth : 2 mm. Depth : 2 mm.
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3 M C O N D IT IO N S C H E C K L IS T
D e fe c t 3 M R e la tio n
S l.n o M o d e M e th o d (P e o p le ) M a c h in e M a te ria l
1 N o tc h in 1g ) N o tc h in g o p e ra tio n to1 ) R ig id c la m p in g o f th e
s ta rt a fte r c o rre c t b u ttin gp ro
o f d u c t d u rin g n o tc h in g
th e p ro d u c t o p e ra tio n .
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Machine NOTCH 1) Clamping of Wrong Check air Air leak noticed Hose
ING the product is pressure replaced & Pr
Location at the pushing
not rigid to ensure od
in the gauge cylinder inlet
Notching uc
due to the hose
condition er
damaged hose
during
machine
start. 46
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PM Analysis
Phenomenon Physically view Contributing Condition Relation with 4M Relation with 4M
(Logical reasoning) (Primary) (Secondary)
Wrong Location Product is shifted from 1) Product is located 1-1) Pusher cylinder 1-1-1) Air pressure Low
notching in it's Location during without butting with stroke length variation 1-1-2) Leak in the Cylinder seal
TATA SCAM Notching operation. the butting reference 1-1-3) Disturbance to the
Products limit switch setting
1-1-4) Dust accumulation in
the guide bushes
1-1-5) Scoring marks in the
A = Feeding Unit guide rod
B = Holding Unit 1-1-6) Leak in the air hose
1-1-7) Scoring marks in the
ID surface of the guide bush.
1-1-8) Leak in the ferrule
1-1-9) Wear in the piston seal
Notching
PM Analysis
Phenomenon Physically view Contributing Condition Relation with 4M Relation with 4M
(Logical reasoning) (Primary) (Secondary)
Wrong Location 2-1-6) Band elongation
notching in 2-1-7) Band fixing hole
TATA SCAM elongataion
Products 2-1-8) Burr in the ID surface
of the product
2-1-9) Clamping cylinder
fixing screw got loosened
2-1-10) Thickness of the
product is less
2-1-11) Clamping cylinder
fixing screw damage
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Fixture Benefits :
Not OK Lining
Wrong Location Notching scrap
eliminated in U Line I Nothcing Machine
Clamping Cylinders
25 Machine
20 15
15 9
10
5 0 0 0 0 0 0 0 0 0
0
Jan-2001
Nov'2000
Jul-2001
May-
2001
2001
2001
Sep-
Mar-
Month
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Poka is a Japanese word meaning “inadvertent errors” and Yoke comes from
Japanese word Yokerie meaning “to avoid”. This has also been termed as
“Mistake / Fool Proofing” or “Fail Safing”. The idea behind poka-yoke is to free
a person’s mind from maintaining repetitive vigil which may be practically
infeasible. By doing so a person without the fear of making mistake can
constructively do more value added activities.
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METHODS
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Example : Prevention
The figure 1-A shows that holes are wrongly drilled due to incorrect
positioning of plate.
Pins
Pins
1 (A) 1 (B) 58
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Example : Detection
Figure 2-A shows that plate with four holes drilled is to be despatched to
the Customer. Customer complaints show many plates with 3 holes
drilled.
Figure 2-B shows the mistake of less drilled holes is detected through a
check by using four locator pins on a gauge.
Pins
2 (A) 2 (B)
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SHUTDOWN
Normal function of machine or process is stopped when defect
predicted/detected.
CONTROL
In Prevention type Poka-Yoke , Control means that even intentional
errors are impossible or methods by which the cause of a defect if
starts happening, it is automatically prevented from happening
(feedback mechanism).
In Detection type Poka-Yoke , Control means that the process is not
stopped but the defective items are automatically separated out and
are not allowed to pass on to next stage
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CONTACT METHOD
These use the principle of physical or energy contact with the product using
sensing devices. They range from guide pins, limit switches, photo electric
beams, etc. Contact methods often take advantage of parts that are
designed with an uneven shape. We can use guide pins or blocks that don’t
allow the product to be seated in a machines jig in the wrong position.
PRESS PRESS
JIG JIG
3 (B) JIG
3 (A) CORRECT INCORRECT
Before After
In figure 3A the Sheet Metal Part A limit switch turns the machine on only
could be placed incorrectly during whenthe protruding neck is positioned
forming operation where it is supposed to be .
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Fixed Value Methods are used when a fixed number of parts must be
attached to the product or when fixed repeats of operations needs to
be done at some process station. Counting devices count the number
of times something is done and signals or releases the product from its
clamping when the required number is reached.
E.g. Before
A tip of spot welding machine wears with use and should be replaced
after certain number of welds. Operator used to forget changing the tip,
resulting in defective product.
E.g. After
A counter, tracking the number of welds, stops the machine and
flashes a light as a signal to change the tip. 63
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This method uses sensors & devices like photoelectric switch connected to a
timer.
E.g. A label dispensing machine uses a photoelectric switch to stop the line if it
does not detect removal of label from the backing tape.
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8 TYPES OF ERRORS
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J
ob
J
ob
F
ix
tu
re Proximity
F
ix
tu
re
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Assembly Errors
This Section consists of examples where operator by mistake does partial or
incorrect assembly.
For Example :
During Assembly of a gear on the shaft for two similar models, Gear ‘B” is
assembled on the Shaft ‘a’ instead of Gear ‘A’. Gear A & B are similar looking
gears differing only in the number of teeth.
To eliminate this error a Mating part is installed on the Assembly fixture
corresponding to ‘A’ to ensure that only gear ‘A’ is loaded
Mating Part
for A
Shaft ‘a’
Before After
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Inspection Errors
Section on Inspection error consists of examples which are related to rejected
components going down the line or to the customer. These errors are due to
monotony and fatigue faced by the inspector.
The operator is not sure of the completion of leakage test and passes them to
the bin meant for keeping jobs that have passed leakage test.
Operator
Leakag Seam sometimes Head that
e welded
Testing jobs not sure of stamps part
Done waiting
for
leakage number
leakag testing test Advances
e
completion
testing when
After it senses
and keeps
Before OK/Not Now Head forno leakageadded
stamping
kept
OK at leakage testing station. Only
Jobs without Leakage Test products in after leakage has been tested
is kept in the OK tray on the the OK OK, job will be stamped by the
left. bin. Head for stamping 69
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Processing Omissions
This section consists of examples where due to mistake, the operator misses
out few steps of the process
Example:
Now the drilling operation has been provided with counter and the job will
not be unclamped unless, the counter with drilling machine reads four.
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Assembly Omissions
The section on Assembly Omissions consists of examples where an assembly
part is not assembled by the operator by mistake and the assembly goes to
next station.
For Example :
In an assembly operation washer were missed before providing nut. To remove
this problem washer picking was sensed to give a start to nut runner.
Washer Sometimes
missed
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For example:
On the cover page of this book an example of carton going
without the medicine bottle inside is shown wherein due to
mistake the packer missed to fill a bottle in the carton.
Now a draft of fan has been provided below the conveyor,
carrying cartons with bottle, which is strong enough only to
blow an empty carton.
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Example: Before
RIGHT WRONG
Notch made on the side
Notch to be made on
opposite to one hole
the side with one hole
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Example: After
Now at notching operation the fixture has been made with 3 pins as shown.
Job with wrong orientation cannot be loaded for Notch operation.
Not possible to
load Fixture for Notch
operation
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