Keikaku Hozen Master Plan
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Keikaku Hozen Master Plan Step
Description
Year 1st
1
Guidance & Support to Jishu Hozen
2
Evaluating Equipment & Grasping present Status
3
Carrying out Zero Failure activities
4
Development of Maint. Information mgt. system
5
Establishing predictive maintenance methods
6
Establishing Lubrication management activities
7
Establishing Spare parts management activities
8
Enhancing maintenance technology &skills
9
Practicing Self management
10
Evaluation of Planned Maintenance
Start
End
2nd
Plan continues
3rd
4th
Detailed Plan : Step-1 Step-1 : Guidance & Support to JH activities
Year 1st
1
Preparing Line Diagrams for training Operators
2
Training operators for finding abnormalities
3
Gathering Past Failures M/C wise, S/A wise, Part wise
4
Study of Past Failures and Countermeasures
5
Removing the Fugai which operator cannot remove.
6
Taking countermeasures for contamination sources and hard to access areas.
7
Helping in making cleaning, inspection and lubrication standards
8
Implementing visual controls in the machines to make inspection easy and quick.
9
Preparing basic training material for different Equipment categories
10
Training to Circle leaders about machine functions & causes of past failures
2nd
3rd
4th
Detailed Plan : Step-2 Step-2 : Evaluate Equipment and Grasp present Status 1
Create and update equipment ledger
2
Decide Equipment ranking evaluation criteria.
3
Rank all Equipments based on criticality.
4
Decide Equipment Failure ranking criteria
5
Rank all past and present failures based on criticality
6
Establish Bench mark and Targets
7
Select appropriate maintenance method
8
Review & revise existing maintenance system
9
Draft the inspection and maintenance standard procedures
10
Select parts and members for TBM activities
Year
1St
2nd
3rd
4th
Train
Detailed Plan : Step-3 Year
Step-3 : Zero failure activities 1St 1
Training Staff / Technicians to do why – Why analysis
2
Restoring unattended deterioration & Elimination of forced deterioration
3
Carrying out Why Ok analysis to check equipment health
4
Analyzing past failures M/c wise, Sub-Assembly wise, , part wise, root cause wise and taking preventive actions
5
Identification & Elimination of week designs / overloading
6
Analyzing current failures & preventing re-occurrences
7
Eliminating Environmental deterioration
8
Reducing / Eliminating manual work
9
Standardizing TBM calendar & Maintenance schedule
10
Horizontal replication of of Kaizen ideas
2nd
3rd
4th
Detailed Plan : Step-4 Step-4 : Develop & Implement maintenance information management system. (CMMS) 1
Build failure data management system.
2
Build & implement equipment maintenance Management system
3
Build & implement System for spare parts management.
4
System for maintenance budget management.
5
System for Lubrication management.
6
System for condition based maintenance management
Year
1St
2nd
3rd
4th
Detailed Plan : Step-5 Step-5 : Establish Predictive maintenance system. 1
Study the need for predictive maintenance & Learn equipment diagnostic techniques
2
Identify components to be diagnosed based on criticality Ranking of components
3
Find out various suitable diagnostic techniques.
4
Prepare CBM calendar and schedule / Implement CBM
5
Find out latest technological development in the field of CBM
6
Research & development of in-house diagnostic techniques.
1st Year
2nd Year
3rd Year
4th Year
Detailed Plan : Step-6 Step-6 : Lubrication management activities 1
Review & revise existing Lubrication management system.
2
Establish & implement lubrication management standards.
3
Investigate & integrate various type of lubricants.
4
Promote visual control systems & easy to lubricate devices to eliminate failures by oil shortage.
5
Systematize lube. Oil purchasing & used oil disposal management.
1st Year
2nd Year
3rd Year
4th Year
Detailed Plan : Step-7 Step-7 : Spare Parts Management Activities. 1
Arranging and reviewing of spare part drawings and details
2
Evaluate existing spare parts management system.
3
Establishing spare parts management criteria (What item, What quantity)
4
Establish spare parts control standards
5
Establish replacement parts management
6
Systemize purchasing system
7
Computerize spare part management system
8
Spare parts inventory & cost control
1st Year
2nd Year
3rd Year
4th Year
Detailed Plan : Step-8
Step-8 : Enhance Maintenance Technology and Skills 1
Training need identification
2
Prepare Training Materials
3
Training for upgrading maintenance Skill & knowledge
4
Training to enhance maint. Technology
1st Year
2nd Year
3rd Year
4th Year
Step 9 is Self Audit: make your own audit points based on the rest of the 8 Steps. (Activities to be done in 8 steps) Step 10 is Evaluation: Checking performance Indicators such as Equipment failure No., MTBF, MTTR, Maintenance Cost, No.of men trained. Etc.
Description
Year 1st
1
Guidance & Support to Jishu Hozen
2
Evaluating Equipment & Grasping present Status
3
Carrying out Zero Failure activities
4
Development of Maint. Information mgt. system
5
Establishing predictive maintenance methods
6
Establishing Lubrication management activities
7
Establishing Spare parts management activities
8
Enhancing maintenance technology &skills
9
Practicing Self management
10
Evaluation of Planned Maintenance
Start
End
2nd
Plan continues
3rd
4th
Detailed Plan : Step-1 Step-1 : Guidance & Support to JH activities
Year 1st
1
Preparing Line Diagrams for training Operators
2
Training operators for finding abnormalities
3
Gathering Past Failures M/C wise, S/A wise, Part wise
4
Study of Past Failures and Countermeasures
5
Removing the Fugai which operator cannot remove.
6
Taking countermeasures for contamination sources and hard to access areas.
7
Helping in making cleaning, inspection and lubrication standards
8
Implementing visual controls in the machines to make inspection easy and quick.
9
Preparing basic training material for different Equipment categories
10
Training to Circle leaders about machine functions & causes of past failures
2nd
3rd
4th
Detailed Plan : Step-2 Step-2 : Evaluate Equipment and Grasp present Status 1
Create and update equipment ledger
2
Decide Equipment ranking evaluation criteria.
3
Rank all Equipments based on criticality.
4
Decide Equipment Failure ranking criteria
5
Rank all past and present failures based on criticality
6
Establish Bench mark and Targets
7
Select appropriate maintenance method
8
Review & revise existing maintenance system
9
Draft the inspection and maintenance standard procedures
10
Select parts and members for TBM activities
Year
1St
2nd
3rd
4th
Train
Detailed Plan : Step-3 Year
Step-3 : Zero failure activities 1St 1
Training Staff / Technicians to do why – Why analysis
2
Restoring unattended deterioration & Elimination of forced deterioration
3
Carrying out Why Ok analysis to check equipment health
4
Analyzing past failures M/c wise, Sub-Assembly wise, , part wise, root cause wise and taking preventive actions
5
Identification & Elimination of week designs / overloading
6
Analyzing current failures & preventing re-occurrences
7
Eliminating Environmental deterioration
8
Reducing / Eliminating manual work
9
Standardizing TBM calendar & Maintenance schedule
10
Horizontal replication of of Kaizen ideas
2nd
3rd
4th
Detailed Plan : Step-4 Step-4 : Develop & Implement maintenance information management system. (CMMS) 1
Build failure data management system.
2
Build & implement equipment maintenance Management system
3
Build & implement System for spare parts management.
4
System for maintenance budget management.
5
System for Lubrication management.
6
System for condition based maintenance management
Year
1St
2nd
3rd
4th
Detailed Plan : Step-5 Step-5 : Establish Predictive maintenance system. 1
Study the need for predictive maintenance & Learn equipment diagnostic techniques
2
Identify components to be diagnosed based on criticality Ranking of components
3
Find out various suitable diagnostic techniques.
4
Prepare CBM calendar and schedule / Implement CBM
5
Find out latest technological development in the field of CBM
6
Research & development of in-house diagnostic techniques.
1st Year
2nd Year
3rd Year
4th Year
Detailed Plan : Step-6 Step-6 : Lubrication management activities 1
Review & revise existing Lubrication management system.
2
Establish & implement lubrication management standards.
3
Investigate & integrate various type of lubricants.
4
Promote visual control systems & easy to lubricate devices to eliminate failures by oil shortage.
5
Systematize lube. Oil purchasing & used oil disposal management.
1st Year
2nd Year
3rd Year
4th Year
Detailed Plan : Step-7 Step-7 : Spare Parts Management Activities. 1
Arranging and reviewing of spare part drawings and details
2
Evaluate existing spare parts management system.
3
Establishing spare parts management criteria (What item, What quantity)
4
Establish spare parts control standards
5
Establish replacement parts management
6
Systemize purchasing system
7
Computerize spare part management system
8
Spare parts inventory & cost control
1st Year
2nd Year
3rd Year
4th Year
Detailed Plan : Step-8
Step-8 : Enhance Maintenance Technology and Skills 1
Training need identification
2
Prepare Training Materials
3
Training for upgrading maintenance Skill & knowledge
4
Training to enhance maint. Technology
1st Year
2nd Year
3rd Year
4th Year
Step 9 is Self Audit: make your own audit points based on the rest of the 8 Steps. (Activities to be done in 8 steps) Step 10 is Evaluation: Checking performance Indicators such as Equipment failure No., MTBF, MTTR, Maintenance Cost, No.of men trained. Etc.
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