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TPM for lean manufacturing
Chap４．Step of “Jishu-Hozen “Activities
Quote From ：TPM Deployment program
TPM encyclopedia Keyword Book
（Japan Institute of Plant Maintenance)
Created by Japanese Gemba Kaizen Web

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４．Step of “Jishu-Hozen “Activities
4.1 ・・・ What is Jlshu-Hozen ？ ・・・・・P62
4.2 ・・・Conservation activities of
manufacturing departments ・・・・・P65
4.3 ･･･Conservation activities
of maintenance department ・・・・・P66
4.4・・・Step method for the development
of “Jishu-Hozen” ・・・・・P67
4.5・・・ Step1： Initial-phase cleaning ・・・・・P69
4.6・・・・Step2：Countermeasures for the source of problems ・・・・P71
4.7・・・Step3： Establishment of tentative standards for“Jishu-Hozen”・P72
4.8・・・ Step4：General [overall] inspection ・・・・・P73
4.9 ・・・ Step5： Autonomous inspection ・・・・・P74
4.10 ・・・ Step6：Standardization ・・・・・P75
4.1１ ・・・ Step 7:Thorough implementation of autonomous ・・・・・P79

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４．１ What is Jishu-Hozen ？
• Keep their equipment by yourself！
・Become operator who can understand
equpment !
Break away from “I am operator and
You are maintenance man”

4.
Jishu-Hozen”
1. Significance of “Jishu-Hozen"
“Jishu-Hozen“ means activities of the
operator that uses maintenance to personally
conduct maintenance activities, including
cleaning, oiling,retightening, and inspection,
thereby raising production efficiency to its
limit. Such activities will prevent forced
deterioration of equipment.
Thus,“Jishu-Hozen” represents activities to
thoroughly eliminate failures, minor
stoppages, defects, and other losses to
restore equipment to their desirable forms,
maintain them, and improve them, and at the
same time to develop “personnel that are
skillful at equipment operations and
improvement.“
“Jishu-Hozen” is the operators work itself. it
is carried out under the step method through
small group activities closely unified with the
managerial structure. it represents a major
characteristic of TPM
PM is designed to pursue production system
efficiency to its limit through “corporate
structural improvement based on the
constitutional
improvement of personnel and facilities," and
"Jishu-Hozen“ itself signifies the onstitutional
improvement of personnel and facilities. This
entails the changing of workers’ ways of
thinking and behaviors,
To attain this, first replace the concept of the
division of labor between operation and
maintenance, represented by the view that “l
am an operator, and you,maintenance man,
fix "it" with the thinking of “protecting one‘s
equipment by oneself.“
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To translate this thought into action, the
development of personnel that are skillful at
equipment operations and improvement is
pushed for, to foster personnel who are
versed in the structure and function of
facilities; who have acquired maintenance
skill to apply improvement.
For the structural reform of personnel, it is
highly effective to bring about the structural
improvement of equipment currently being
used. in “Jishu-Hozen“, as the first step to
“protect one’s equipment by oneself," work
should be started with improvement of basic
conditions of the equipment being used
(cleaning, oiling, and retightening). Then,
based on the step
method, structural improvement of quipment
should be effected so that
the equipment will be the form as it should
be. As a result, overall equipment efficiency
will improve greatly, and the operator
personally experiences the effect of “Jishu-
Hozen", so that his “structure” will be
changed so as to protect his own equipment
by himself. Thus, in “Jishu-Hozen", the
constitutional improvement of personnel and
equipment proceed simultaneously.
Also, “Jishu-Hozen" is a self-management
activity by small work-site
groups. Keys to the activation of small
groups are said to be “morale,
skills, and places for actions.” The
prerequisite is creation of the “places for
actions,“ and introducing only “Jishu-Hozen"
would prove ineffective.
it should be promoted as one of the five
pillars (or eight pillars) of TPM development
of the entire company/establishment.
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４．２ Conservation activities of
manufacturing departments
1. Activities to prevent degradation
① Correct operation
② Cleaning, Refueling, Retightening
③ Adjust
④ prediction of abnormal
⑤ Recording Data of conservation
２．Activities to measure the degradation(By five senses)
①Daily check
②Periodic check
３．Activities to recover the degradation
①Easy replacement of parts, emergency response in the event of failure
②Quick communication for failure
Important is prevent degradation

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４．３ Conservation activities
of maintenance department
High Conservation activities
①Focused on the areas that require high technology
Periodic maintenance, predictive maintenance, corrective
maintenance
２．Support for Conservation activities of manufacturing section
① Education equipment function
② education bolts and nuts
③ Education of lubricating oil
④ skills education inspection
⑤ One Point Lesson
Important is measure and Restoration of
Degradation

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４．４ Step method for the development
of “Jishu-Hozen”
1st step: lnitial cleaning (cleaning/inspection)
While thoroughly eliminating dust, dirt, etc,
from inside the cover and cleaning every
corner of the equipment, detect and correct
equipment nonconformity/latent defects for
restoration, oil, and retighten, through
cleaning, and thereby prevent forced
deterioration.
2nd step: Countermeasures for contamination
sources and hard-to-access areas
Detect sources of dust and stains, prevent
scattering of dust, and improve hard-to-access
areas for cleaning, oiling, retightening, or
inspection, and shorten time for these
activities.
3rd step: Preparation of the tentative
standards for “Jishu-Hozen"
Prepare action standards to be observed by
oneself, so that cleaning,oiling, retightening,
and inspection can be surely performed in a
short period of time.
4th step: general inspection
To improve equipment efficiency to the limit,
understand the structure, functions, and
principles, and how the equipment should
be; inspect the main mechanism and parts
that constitute the equipment with the eyes of
an “operator skillful at equipment operations
and improvement" without exception; detect
latent
defects; and restore or improve the equipment
to desired conditions.
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5th step: Autonomous inspection
Review the tentative autonomous standards
and general inspection standards, prepare
“Jishu-Hozen” standards that provide for the
efficient of inspection and prevention of
inspection errors, and maintain the equipment
in its desirable conditions.
6th step: Standardization
The items to be controlled at work sites
include raw materials/products, dies/jigs/tools,
measuring instruments,cleaning/inspection
outfit, and transport equipment, in addition to
facilities. They also include written work
standards and records.
Review and standardize them, and strive for
zero losses.
7th step: Through implementation of self-
management
With self-confidence, based on past results
obtained by changing
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lnitial cleaning, Countermeasures for contamination sources,
Preparation of the tentative standards for “Jishu-Hozen“,
general inspection, Autonomous inspection, Standardization,
Through implementation of self-management

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４．５ Step １：Initial-phase cleaning
Cleaning is inspection
The 1st-step activity of “Jishu-Hozen". It
aims to totally eliminate accumulated dust
and stains by thoroughly cleaning all parts of
equipment;
to find latent detects of the equipment, such
as contamination sources,hard-to-clean
areas, and nonconformities that may cause
failures/detects or accidents through
cleaning activities; and to take corrective
steps about the problems which they think
they can fix. Discovered nonconformities and
their contamination sources are highlighted
by attaching ‘efu' (tags) to them.
Cleaned portions naturally get dirty again as
a result of production activities, and it is also
an important activity to measure the time
until they
become dirty and how dirty they are, and to
study steps to prevent the occurrence at
stains.

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４．６ Efu / Tag
A tag, equivalent in size to the one affixed to
baggage, is attached to nonconformity
detected for marking. These tags are
classified into white efu and red efu. White
efu is attached to the location at
nonconformity that can be rectified by
operators in “Jishu-Hozen“, while red efu is
attached
when maintenance workers must be called
in for fixing. On the front at efu,
the date of nonconformity detection, the
finder, and the content of nonconformity
should be entered, with an illustration of the
nonconformity added.
On the back of the tag, the content of the
required improvement should be entered.
After an improvement step is completed, the
tag should be withdrawn, and the results of
the step should be additionally recorded.
Unremoved etu indicates that no corrective
measures have been taken as yet, so the
tags
remaining number of nonconformities to be
addressed.

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4.7 Step2：Countermeasures for the source
of problems
Activities in the 2nd step of “Jishu-Hozen".
They consist at work to improve sources of
dust and stain detected in the 1st step; to
prevent dust,
stain and dispersion and clean the places;
and to improve locations where oiling is
difficult, so as to reduce time for cleaning or
oiling and enhance
equipment maintainability‘ Where cleaning
is difficult, improvement may be made at
cleaning tools and/or methods at cleaning.
Also,lone can measure the cleaning time
required to realize the state of cleanliness
where a malfunction can be detected while
operating the equipment, so as to reduce
such a cleaning time.
The target “maintenance cleaning time"
should be five minutes per day, per
operator and two hours per month, per
operator; one should repeat improvements
until these targets are attained,This is a
step where brain rather than money should
play a role.

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4.8 Step３： Establishment of tentative standards
for “Jishu-Hozen”
Establishment of tentative standards for
“Jishu-I-lozen”
The 3rd-step activities of “Jishu-Hozen".
Members should work out provisional
cleaning standards to maintain the 1st-step
level for approved
cleaning and the 2nd-step level for machine
conditions that have dealt with contamination
sources/hard-to-access areas; to clean and
inspect daily or regularly; to repeat
improvement; and to ensure prevention at
equipment
degradation. it is also necessary to review oil
supply and lubrication conditions, to detect
and rectify nonconformities and hard-to-oil
and-inspect spots, and to prepare provisional
oiling standards, thereby seeking the
improvement of equipment reliability and
maintainability and completing standards that
can be easily kept
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Activities to be implemented as the 4th step
in “Jishu-Hozen", designed to “foster
operators really skillful in equipment
operations improvement."
Operators should study and understand the
structure, functions, and principles of
equipment, as well as its desirable
conditions; inspect
principal mechanisms/parts that compose
the equipment, thoroughly and without
omission, from the eyes of skillful operators;
reveal potential
defects; and restore original conditions.
The operators should be trained regarding
such items as machine elements,
lubrication, pneumatic pressure, hydraulic
pressure, electricity, driving mechanism,
equipment
safety, and processing conditions; they
should conduct inspection regarding these
items, and learn skills to find nonconformity.
Also, while
inspection standards are prepared to ensure
conformance, equipment should be
improved for easier inspection, and ideas for
visual control
should be embodied.
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4.9 Step4：General [overall] inspection
Education

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5.0 Step5： Autonomous inspection
Activities to be conducted as the 5th step for
“Jishu-Hozen“. Based on the experience in the
1st to 4th steps, circle members should review
the
present written standards on cleaning, oiling,
and general inspection from
the viewpoints of:
[1] zero failures/detects,
[2] inspection efficiency improvement,
[3] inspection work load balance, and
[4] visual control.
Operators should also clarity the work-task
sharing with the maintenance
department for each equipment, upgrade the
standards with inspection efficiency
improvement and error-free inspection to be
completed as
autonomous inspection standards.
Also, they should further study equipment
operation and relations between quality and
equipment, thereby developing capability oi
right operation and early detection of
abnormalities.
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4.10 Step６：Standardization
(“Jishu-Hozen”)
The 6th step of “Jishu-Hozen”. While steps to
5 involve activities that focus on
improvement and inspection of basic
equipment conditions, the6th step aims at
ensuring that these steps are taken as a
matter of course for control purposes, that
the role of operators will be extended over
and beyond equipment operation to
include that of reducing losses
aggressively and that "jishu-Hozen" will
take place to the fullest extent.
Specifically, this step involves overall review
and systematization at various
maintenance and control device such as
physical distribution standards, data
records, standards die/jigs/fixtures,
standards and the like

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4.11 Step 7:Thorough implementation
of autonomous
Activities at the final seven-step stage at
“Jishu-Hozen". Here, all the activities
performed this far are boiled down,
and improvement is repeated
through small group autonomous
management activities.
Although the word "autonomous" is used,
the small-group activities are basically
tied to the
company policy and targets, so that
whatever these small groups may
establish as circle targets, whatever
they may take up as improvement
themes,
and whatever autonomous activities they
may continue to attain more efficient
production — in other words, all such
activities operational for upkeep and/or
improvement — should become part of
the company operations.

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