Professional Documents
Culture Documents
MAINTENANCE\
(Pemeliharaan Mandiri)
(Step 0-3)
AUTONOMOUS MAINTENANCE
Kinerja
FI
Standard
Kerusakan normal
Forced
Deterioration
PM
AM
2
JISHU HOZEN
PENGERTIAN
Pemeliharaan mandiri adalah kegiatan dimana
setiap karyawan melaksanakan tugas-tugas
harian pada peralatannya sendiri yang
meliputi inspeksi, pelumasan, penggantian
komponen, reparasi, mengatasi gangguan, uji
akurasi, dll dengan tujuan agar kondisi
peralatan dapat dijaga sendiri kondisinya oleh
si pengguna.
Saya menjalankan,
Anda membenarkan
Saya menjalankan,
Saya membenarkan
3
Tujuan Program AM
Step (Tahapan) AM
STEP. 7
STEP. 6
STEP. 5
STEP. 4
Autonomous Inspection
(Lakukan Inspeksi langkah S1-4 lagi)
General Inspection
(Standarisasi alat, Lingkungan kerja & proses kerja)
Baby log
book
Kunjungan rutin
vaccines
Step 5
Berbagi tanggung jawab!
Step 0
Persiapan
untuk sangg bayi
y
Step 1
Pembersihan awal
Step 2
Mencari sumber masalah/
area yang sulit di akses
Step 4
Meningkatkan pengetahuan!
Step 3
Mempelajari yg
harus dilakukan/diinpeksi 6
O
Orang
tua
D k
Dokter
Mesin
Operator
Teknisi
7
Tiga Mahkota AM
3 Mahkota AM:
Activity Boards (Papan Circle)
One-Point
One Point Lessons (OPL)
Team Meetings (Circle Meeting)
Daftar Tag
Defect
Step 2
No. of OPL
St 3
Step
OPL
Defect
Logo Tim
Graph
Peta/Gambar
Section Policy
1. ---------------2. ---------------3. -----------------------------------
Team Policy
Issues:
-----------------Policy:
Target
Daftar
Jadwal aktivitas AM
Safety
Safety
Sumber
pengotor
Sumber
pengotor
Defect kritis
Defect kritis
Standar Antara
Graph
No. of Tag
Daftar
CLI std,
procedure
Graph
KAIZEN
AM Step 01 02
-1
1
-2
-3
-4
4
-5
-6
-7
2001
---- Month ---
2002
12 01 02
----------
11
Line
A Step-1
Step 2
Step-2
Step-3
--------------------------------B Step-1
Step-2
Step-3
---------------------------------
2001
01 02 03 04 05 06 07
12
Waktu
120
100
dengan
g aktivitas AM.
80
Meeting
Improvement
Cleaning
60
40
20
0
Jan
Feb
Mar
Apr
May
Target
13
No. of Tag
400
Kemampuan Operator:
Mampu menemukan defect
350
No. of
Tag on
300
250
200
No. of
No
Tag off
150
100
Kemampuan Operator:
Mampu memperbaiki defect
50
0
Jan
Feb
Mar
Apr
May
Target
14
AM Activity Time
100
90
Meeting
80
70
60
Improvement
50
40
30
Cleaning
20
10
0
Jan
Mar
No. of Tag
120
100
80
Tag off
60
Tag on
40
20
0
Jan
Mar
15
Daftar Bahaya
Line Name:
Team Name:
Equipment:
No.
Location
Description
Date
Countermeasure
Request to
Name
Deadline
Completed
16
Team Name:
Equipment:
No.
Location
Description
Date
Countermeasure
Request to
Name
Deadline
Completed
17
Team Name:
Equipment:
No.
Location
Description
Date
Countermeasure
Request to
Name
Deadline
Completed
18
Team Name:
Equipment:
No.
Location
Description
Date
Countermeasure
Request to
Name
Deadline
Completed
19
No. of OPL
160
140
IImprovementt
Safety
Defect
120
100
80
60
40
20
0
Jan
Feb
Mar
Apr
May
Target
20
Date:
Equipment:
Team Name:
Before
Comment:
After
Comment:
Benefit:
21
Lublication
Inspection
Cleaning
140
120
100
80
60
40
Step-3
May
Apr
Mar
Feb
Jan
20
Selama operasi/tidak
p
Berapa lama
Kondisi yg benar
C le a n in g
D r a w in g
L u b r ic a tio n
I n s p e c tio n
L o c a tio n
--------------------------------------------------------------------------------------------
S ta n d a rd
-----------
W hen
H ow
M e th o d
T im e
P e r io d
Pd operasii shift,
hift tambahkan
t b hk kkolom
l
shift
hift
23
24
25
Tanda Tangan
Nama
26
Meetings
27
AUTONOMOUS MAINTENANCE
Step 0 & 1
28
JISHU HOZEN
29
Personil
- Menyentuh peralatan mengembangkan rasa memiliki terhadap peralatan
- Melatih mata untuk mendeteksi fuguai dari peralatan
- Mempelajari fungsi dan struktur dari peralatan
- Mengetahui titik lemah dari peralatan
30
Pembesihan
Pengecekan
Menemukan abnormality
Mengembalikan ke kondisi semula & improve
Efek Positive
Kebanggaan
Rasa memiliki
Disiplin
Tanggung Jawab
Kebiasaan
Perilaku
Budaya
32
Daftar area
yg defektif
Identifikasi area
yg sulit dibersihkan
D ft area yg sulit
Daftar
lit
Sumber kontaminasi
Yg terlihat
Daftar sumber
kontaminasi
Normal? atau
Abnormal?
D ft pertanyaan
Daftar
t
NO
ATTACKING
DIRT
YES
REDUCE
NO
COUNTER
MEASURES
FOR
HTC
AREA
YES
CONTAIN
NO
GUARDS
YES
SCREEN
YES
PAN/TRAY
FAN/CHIMNEY
NO
DIRECT
34
TPM
TPM
Step No: 1 2 3 4 5 6 7
Step No: 1 2 3 4 5 6 7
ABNORMALITY
ABNORMALITY
Equipment:
Control No:
Date Found:
Found by:
Description of Abnormality:
Equipment:
Control/PK No:
Date Found:
Found by:
Description of Abnormality:
35
TYPE
1
TYPE
2
TYPE
3
TYPE
4
TYPE
5
TYPE
6
TYPE
7
DUST
LOOSE
MISSING
HOLES
EXCESS NOISE
HARD TO PERFORM
OTHERS
DIRT
CHATTERING
WEAR
EXCESS HEAT
JH ACTIVITY
SPILLAGE
ECCENTRIC
CHIPPED
ODOUR
LEAKAGE
INCLINED
BENT
DISCOLOURATION
SCRATCH
VIBRATING
BROKEN
RUST
EXCESS MOMENT
DENTED
TOTAL
TAGS
ATTACHED
SPLASH
LOCATION OF FUGUAI
EXTERNAL SURFACE
OF EQUIPMENT
WIRINGS,VALVES,3-POINT
SET,ETC
DOORS/INSIDE OF
SAFETY COVER,OPERATION/
COVERS
CONTROL PANEL,INSPECTION
HOLE,ETC
ASSOCIATED
WORING OIL,LUBRICATION
EQUIPMENTS
TANK,HYDRAULIC UNIT
ETC
PERIPHERAL
MEASURING INSTRUMENT,JIGS
EQUIPMENTS
TRANSPORTATION
CHUTE,CONVEYORS,
SYSTEMS
TURNTABLES ETC
TURNTABLES,ETC
AROUND EQUIPMENT
GEARS,CAMS,CHAINS,SHAFT
MACHINE PARTS
PULLEYS,SPROKETS,ETC
36
Activity
Month 1
Month 2
Month 3
Month 4 Month 5
Meeting of circle
Preparation of OPL
Finish of activity
Sustain activity
Activity inprocess
37
HLL - Silvassa Beverages
Activities
After
Complete
p
Participation
p
from Circle
Teams and Line Management
Basic awareness provided to the
operators about the Step 1 Aims and
Objectives
38
Identifikasi
Fuguai
Pembuatan
T
Tag
Diskusi dengan
tim engineering
Pembuatan
K i
Kaizen
Eliminasi
F
Fuguai
i
Update
progres ke
tim circle
Logging of
Result;
Know-Why
OPL;
standar
t d CLTI
Tag dikonversi
menjadi kaizen
39
40
In Association with
41
In Association with
Lihat
Dengar
Cium
Sentuh
Rasa
42
In Association with
5 INDRA
43
In Association with
Pembongkaran bagian utama dari mesin, dan jika mungkin, temukan defect
yang terlihat seperti yang telah dilakukan pada tahap 1
z Tahap 4 - Pembersihan (fase kedua)
44
In Association with
45
In Association with
Da
aftar Area yg
Su
ulit dijangkau
Daftar Sum
mber
Kontamina
K
asi
46
DG Area
Compressor Area
47
Group :
Panther
Prepared :
Leader :
16.11.2000
Revised :
Flex
Tag No :
Location :
Packing Hall
TPM
HORIZONTAL SEALER
VERTICAL SEALER
FILLING NOZZLES
MAIN DRIVE
Standard
Method
Tool
Action if
Required
Time
(Min)
Interval
Responsibility
Shift
Daily
Weekly
Monthly
Quarterly
Sealing Surface
No lamination,No
shampoo
Clean
Batch cutter
blade
No Lamination,no
shampoo,
Clean
2 minutes
D69,D110,D304
Roller
Roller.
No Dust , No Dirt
Dirt.
Clean
2 Minute
Sealing jaws
No laminate,No
smampoo,
Clean
1 minutes
No shampoo
Clean
2 minutes
D86,D302,D417
Clean
2 minutes
D69,D110,D306
Clean
2 minutes
D86,D302,D417
Clean
3 Minutes
Flexible Hose
Motor
No dust,
Clutch break
assembly
No dust,
Colleting drive
No shampoo,
,
,
2 minutes
D254,D246,D122
D254,D246,D122
D254,D246,D122
Dancing roller
No Dust
Clean
Inside area
No Dust
Clean
2 Minutes
D86,D302,D417
48
Autonomous Maintenance
Step
p 02
Eliminasi area yg sulit dijangkau
dan
sumber kontaminasi
49
T j
Tujuan
Tahap ini bertujuan menghilangkan sumber-sumber pengotoran
dan pengkerakan serta berusaha memperbaiki bagian-bagian yg
sukar dibersihkan atau dilumasi sehingga pelaksanaan
pekerjaan-pekerjaan
k j
k j
it lebih
itu
l bih mudah
d h dan
d cepat.
t
50
BEFORE
AFTER
BEFORE
AFTER
51
BEFORE
Covers on the sides of Roll Mill made transparent for ease in inspection
BEFORE
Roll Mill Motor relocated to the top to eliminate Hard to Access Area
during cleaning and inspection
AFTER
AFTER
52
BEFORE
AFTER
BEFORE
AFTER
53
BEFORE
AFTER
BEFORE
AFTER
54
BEFORE
BEFORE
AFTER
AFTER
55
56
After
57
Before
After
58
After
59
After
60
Before
61
AUTONOMOUS MAINTENANCE
CLI Standards
62
T j
Tujuan:
Mempertahankan apa yang telah dicapai pada tahap 1 dan tahap 2.
2
Selain itu juga meningkatkan keandalan peralatan dengan
membuat serta melaksanakan standard sementara yg dapat
dilakukan dengan mudah.
Standard meliputi Pembersihan (Cleaning), Pelumasan
((Lubricating),
g), dan Pengencangan
g
g Baut-baut ((Tightening)
g
g)
63
CLIT* tidak
dilakukan
70%
Kerusakan yg
tdk dipantau
Skill yg buruk
b k
Tidak mengikuti
prosedur operasi
((SOP))
30%
Masalah yang hanya
dapat dicegah oleh bagian
engineering (produksi dan
maintenance)
*CLIT
CLIT = Cleaning (Pembersihan)
(Pembersihan), Lubrication (Pelumasan)
(Pelumasan), Inspection (Inspeksi)
(Inspeksi),
Tightening (Pengencangan)
64
In Association with
65
Area:
H&B:
TSO:
Line #
Line Leader
Machine
Bejo
1st Draft
nd
Filler /Capper
Ref Drawing:
No
Location
M/C
Status
Inspection
Action
Method
C
L
E
A
N
I
N
G
1.
Filler vacuum
pot.
Cleaned free of
liquid
Stopped
Visual
2.
Capper
vacuum pot
Cleaned free of
plastic debris .
Stopped
Visual
3.
Filler bed
Stopped
Visual /
touch
4.
Filler doors
Stopped
Visual
5.
Keystation
Clean free of
product
Running
Visual
/touch
6.
Cleaned free of
product
Stopped
Visual
/touch
7.
Cap Plate
Stopped
Visual
Date:
P. Schier
15/12/97
M. Bite
19/01/00
Draft
Revision 2:
Standard
Compiled By:
Time
Mins
Tool(s)
Intervals
D
Person in
Charge
M
Hot water
2min
Operator
Hot water
2min
Alcohol and
paper towel
5min
Operator
5min
Operator
Alcohol and
paper towel
2min
Alcohol and
paper towel
5min
Operator
Alcohol and
paper towel
1min
Operator
Operator
Operator
66
A rea:
H&B:
T SO :
L ine #
L ine L eader
M achine
Pat C olem an
1 st D raft
Filler /C apper
R ef D raw ing:
No
Location
nd
M/C
Status
Inspection
Action
Method
1.
I
N
S
P
E
C
T
I
O
N
2
2.
3.
4.
5
5.
6.
7
7.
Capping plate
leads
C
Compressed
d
air valve
Oil gauge
vacuum pump
Guarding bolt
around filler
Pl t & plate
Plates
l t
cover
Gearbox oil
gauge (rear of
filler)
Compressed
air pot
8.
Capping head
9.
Capping plate
leads
Filler guide
rails
10.
Stopped
Check
Ch
k if iin green
zone
Check if in zone
D ate:
P. Schier
15/12/97
M . B ite
19/01/00
D raft
R evision 2:
Standard
C om piled B y:
Time
Mins
Tool(s)
Intervals
D
Person in
Charge
M
None
1min
R
Running
i
Visual /
touch
Vi l
Visual
N
None
1 i
1min
O
Operator
t
Running
Visual
None
1min
Operator
Check no screws or
bolts missing
Ch k ffor
Check
burrs,chips or
plastic shavings
Check oil level is
between markings
Running
Visual
None
1min
St
Stopped
d
Visuall /
Vi
touch
N
None
5 i
5min
Running
Visual
None
1min
Check that it is
filled to marking
and is not damaged
Check the end of
nozzle for burrs
Check leads are not
damaged
Check are not
damaged
Running
Visual /
touch
None
1min
Operator
Stopped
Visual /
touch
Visual /
touch
Visual
None
1min
Operator
None
1min
None
2min
Stopped
Stopped
Try turning
screws by hand
Touch to see if
leaking
Operator
O
Operator
t
Operator
Operator
Operator
Operator
67
68
69
Drawings CLI Standards and CLI calendar are located at the line
Drawings,
70
71
74
75
76
77
AM Step 1-3
- Kondisi Dasar Mesin yang baik bisa dicapai dengan melakukan
cleaning (5S) dan inspeksi
- Adanya sistem utk mempertahankan kondisi yang sudah dicapai
- Hasil Nyata yang bisa dilihat dari TPM
AM S1
Pembersihan Awal
Cleaning
Daftar Abnormalityy
Tagging
Minutes Meeting
AM S2
Sumber pengotoran
& daerah
d
h yg sulit
li
dibersihkan
Check list
FI
OPL
AM S3
Standar Antara
Check list & Standar:
- Pelumasan
- Kebersihan
- Pengencangan baut
78