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TPM Club India Quality Maintenance Pillar

PILLAR

Hinshitsu Hozen

or

Quality Maintenance

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Confederation of Indian Industry
TPM Club India Quality Maintenance Pillar

Hinshitsu-Hozen
What is Hinshitsu-Hozen?

To maintain integrity of quality (state of 100% non-defectives)

* 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
Confederation of Indian Industry
TPM Club India Quality Maintenance Pillar

Hinshitsu Hozen Concept


Quality Defect Factors
Caused by raw material Caused by equipment Caused by method Caused by conditions of
conditions precision conditions people involved

Procuring/Producing Manufacturing equipment Devising methods not to Fostering operators


materials not to generate not to generate defect generate defects proficient in equipment
defects and job

Quality Assurance
Jishu-Hozen activities
+
+
Equipment and Design check Material Skill Education and Training
environment management Management

PM Pursue relationship between quality Maintenance and


Analysis characteristics and material and energy management ability training
condition / equipment precision / method (Ability to find cause system
conditions
troubles and to quickly and
correctly take actions)
Set conditions of equipment not to
generate defects

Management of conditions not to generate


defects

(Hinshitsu Hozen) Zero quality defects JIPM, 1987 3


Confederation of Indian Industry
TPM Club India Quality Maintenance Pillar

Implementation Procedure for


Quality Maintenance
Understanding quality defect phenomena.

Prepare QA Matrix.

Set 4M conditions.

Identify Process Point.

Conduct PM Analyses.

Identify Q-components

Prepare QM Matrix.
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Confederation of Indian Industry
TPM Club India Quality Maintenance Pillar

QM Master plan

Master Plan for quality maintenance is planning of various

activities in this pillar with respect to the time frame in

months and years. According to the stage of TPM

implementation it can start at various levels. In the

beginning it will start with data collection on defects to

improving conditions to sustaining zero defect conditions.

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Confederation of Indian Industry
TPM Club India
TPM Steps for QM-Pillar Quality Maintenance Pillar

Step-1 : Understanding the Defect


-Q Characteristics
-Defect Characteristics
-Defect Mode
-Defect Phenomenon.
-Data Collection.

Step-2: QA Matrix
-Defect Mapping
-Defect Characteristics Vs Sub process
-Defect Mode Vs Support Process.

Step-3: Analyse 4M conditions.


-Prepare draft of 4M conditions.
-Status of 4M conditions.
-Survey of 4M conditions.
-Identify the gaps in 4M conditions.

Step-4,5 & 6: Problem countermeasure and restoration.


-Why-Why Analyses .
-Quality improvements through Kaizens.
-PM Analyses.

Step-7,8 & 9:
-Component Function
-Identify Process Point.
-Identify Q-components.

Step-10: QM Matrix

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TPM Club India Quality Maintenance Pillar

Defects classification
A - Type defect B - Type defect C - Type defect
OK OK NOT OK

NOT OK NOT OK

Action No action Action


taken by OK
by operator taken by
operator operator

LSL OK USL OK
LSL USL OK
LSL USL

The output is (OK) initially The output is (OK) initially


Becomes (NG) Becomes (NG) The output is (NG) initially
Corrective action is taken No action taken by Action taken by operator
by operator operator Becomes (OK)
Becomes (OK) Becomes (OK) (setting scrap)-Why-Why
Uue Why Why Analysis Use PM Analysis 7
Confederation of Indian Industry
TPM Club India Quality Maintenance Pillar

Understanding Defect Phenomenon

Defect Phenomenon is defining the defect characteristics in the form of defect mode.
Phenomenon can be defined in 5W & 1H style (means What, Where, When, Which,
Who, How much)

1. Quality Characteristics (From Customer or for customer). For e.g. Smooth Shifting of gears.

2. Defect Characteristics (Not achievement). E.g.-Shifting not ok/Shifting Bad.

3. Defect Mode (Modes of defect Characteristics). E.g- Shifting hard, shifting loose.

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Confederation of Indian Industry
TPM Club India Quality Maintenance Pillar

Drafting of QA (Quality Assurance) matrix and


reflection in standards

QA Matrix is prepared to establish the relationship between

defect / defect mode and the process which causes it. It

requires data collection for defects at various process

stages to prepare a QA Matrix.

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Confederation of Indian Industry
TPM Club India Quality Maintenance Pillar

QA Matrix
Quality Characteristics-Proper tightening of bolt
Defect Characteristics- Improper tightening
Defect Modes
Quality
Support
Process Sub-Process Index
Process
(Process)
Mode-2 Mode-4
Mode-1 Mode-3
Excess Washer
Bolt loose Bolt broken
Tightening flared

Rear Wheel
Nut Runner Air-Pressure 4
Fitment
Tightening
4
speed
Torque wrench Torque value 4
Bolt Bolt size X X 2
Washer Washer Size X X X 1



Quality Index (Defect) 4 3 4 4 15

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TPM Club India Quality Maintenance Pillar

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Confederation of Indian Industry
TPM Club India Quality Maintenance Pillar

Why-Why Analyses Sheet-Defect


Product Date Time:
Machine M/c No.
Defect
Previous Occurance
Phenomenon

Why Due to Date:


Effectiveness (Why Not
Why 1 OK)
Why 2 Counter measures Details
Why 3
Why 4
Why 5

Root Cause

Root Cause Due to Tick Root Cause (Due to) Tick Particulars
1. Poor Basic condition Man Kaizen Idea No.
2. Poor Operating
condition Machine OPL No.
3. Deterioation Material PM Calender
4. Weak Design Method Jishu Hozen
5. Poor Skill Horizontal Deployment Possible Yes/No

Prepared by
Department Head

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TPM Club India Quality Maintenance Pillar

Component function Analyses

Machine-Systems-Assemblies-Components

Actual Failure is Component failure not the machine.

Defect-Component malfunction-Component failure.

Part Problem/Defect Extent of function Inspection period


Function
Name Caused degradation specified/actual









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TPM Club India Quality Maintenance Pillar

Process Point Analyses Report

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Confederation of Indian Industry
TPM Club India Quality Maintenance Pillar

Quality Component

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Confederation of Indian Industry
TPM Club India Quality Maintenance Pillar

QM Matrix: To relate the malfunction of component (abnormality ) with defect mode.

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