Transcript T.P.M. Kaizen forms

Kaizen
TPM Forms
FORMS
Effectiveness Improvement Sheet
Date:
Eater
Department:
Machine:
Problem Description and suggested improvement
Breakdowns,
Start-up
Tool
Change
Set-up &
Adjustment
Idling,
minor
stoppages
and speed
loss
Scrap &
Rework
Process owner
Improvement
Dates
Improvement
Measurement
Job begins
on the
Time Before
Job ends
on the
Time After
Job begins
on the
Time Before
Job ends
on the
Time After
Job begins
on the
Time Before
Job ends
on the
Time After
Job begins
on the
Time Before
Job ends
on the
Time After
Job begins
on the
Time Before
Job ends
on the
Time After
Responsible for follow-up
CAPABILITY ANALYSIS
Machine Number:
Checked by:
Date:
Mach. Name:
Controller:
Unit/Cell:
Axis:
Direction:
Tolerance req.:
1. Warm up the machine
2. Select an axis and a direction
3. Position / affix reference block (s) on the table
4. Position / affix mag-base / indicator on head or table
5. Move head out to a distance beyond typical work zone
0 A B C
6. "Zero out" indicator and controller ----------------------------->
|___|___|___|
7. Move head out to a distance beyond work zone again
8. Bring head up to indicator until controller reads zero
9. Record indicator reading
10. Repeat step 9 for the next 9 readings
11. Validate initial zero indicator
12. Perform test on all axes for minus and plus directions
NB NB Indicator needle should be at 10 to 15 degrees to face to be inspected.
Indicator rod should be less than 3 inches
Cycle
Specified pos.
Actual pos.
Difference
1-
2-
3-
4-
5-
6-
7-
8-
9-
10-
====>>>
Total
Average (accuracy)
Stray test (avg * 3.267)
Std. dev. (repeatability)
6s (or axis capability)
% of Tolerance
<====
<====
Max:
25%
Abnormalities identifier: screws, nuts and bolts
Abnormalities
identified:
Total
Total
Bolt too
short
Broken
bolt
Total
Total
Missing
bolt
Total
Crooked
bolt
Total
Loosened
nut
Missing
nut
Total
Total
Damaged
head
Misaligned
bolt
Total
Total
Misaligned
nut
Damaged
nut
Total verified:
OTHERS
Marked
bolts:
Verified but non critical
(white dot)
Missing without consequence
(yellow circle)
Maintenance only
(red dot)
Maintenance alone and tightening
mark (red dot, white line)
Critical or subject to loosening
(yellow dot)
Verify tightening daily (yellow dot,
white line)
CHECK LIST (AUTONOMOUS MAINTENANCE)
Line
No
ITEM
Machine
ACTION
page
/
Build Year
Frequency Duration
Who
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
10
10
* Upon a power shutdown, apply padlocking standards
Frequency:see example on back
Fill the report daily
Month:
Date
Inspected by
Day
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Inspection frequency example
Daily inspection
D
(Daily)
Weekly inspection
D2
(on second day of the week)
Monthly inspection
W3,D1
(on the third week,
first day of that week)
Yearly inspection
M6, W1, D2
(on the 6th month,
the first week of that month,
the second day of the week)
Daily lubricant log book
Month/Year
Indicate the quantity used
Specify:
litres: l
millilitres: ml
Norm. Temp.
Department
Lubrication
Oil
Hydraulic
Oil
CODE
Machine Code
CODE
Norm. Temp.
Gear Oil
CODE
Grease
CODE
Day
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Lubrication
Oil
Hydraulic
Oil
Day
CODE
Norm. Temp.
CODE
Norm. Temp.
Gear Oil
CODE
Grease
CODE