Keikaku Hozen Master Plan

Step Description Year

1st 2nd 3rd 4th

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 Plan continues

Detailed Plan : Step-1Step-1 : Guidance & Support to JH activities Year

1st 2nd 3rd 4th

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

Detailed Plan : Step-2

Step-2 :

Evaluate Equipment and Grasp present Status

Year

1St 2nd 3rd 4th

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

Detailed Plan : Step-3Step-3 : Zero failure activities Year

1St 2nd 3rd 4th

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

Train

Detailed Plan : Step-4

Step-4 : Develop & Implement maintenance information management system. (CMMS)

Year

1St 2nd 3rd 4th

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

Detailed Plan : Step-5

Step-5 : Establish Predictive maintenance system.

1st Year 2nd Year 3rd Year 4th Year

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.

Detailed Plan : Step-6

Step-6 : Lubrication management activities

1st Year 2nd Year 3rd Year 4th Year

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.

Detailed Plan : Step-7Step-7 :

Spare Parts Management Activities.

1st

Year

2nd

Year

3rd

Year

4th

Year

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

Detailed Plan : Step-8Step-8 : Enhance Maintenance Technology and Skills

1st Year 2nd Year 3rd Year 4th Year

1 Training need identification

2 Prepare Training Materials

3 Training for upgrading maintenance

Skill & knowledge

4 Training to enhance maint. Technology

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.