How to realizing zero failures in production system.Practical step to implement in shop floor activity.
Step 1 Sorting out of past failures
Classification of recurring or sudden , difficulty, occurrence portions , failure modes
Step 2 Failure analysis and overall inspection
Re-analysis of recurrent failures
Thorough analysis of new failures
Step-3 Elimination of forced deterioration and rectification of unattended deterioration
Finding minor defects through cleaning
Improvement Basic Condition
Studying use condition
Educational guidance regarding minor defects & use condition.
Elimination of forced deterioration in unseen portions
Early Rectification of deterioration that have been identified
Step 4 Study of weak points
Implementation of improvement (Countermeasures for SOC and HTA)
Sorting out and correcting design weak points
Study of steps for extending service life
Structural improvement
Step 5 Preparation and control of standard documents
Preparation of jishu hozen standard document
Check list based inspection and rectification of deterioration
Inspection and correction of malfunctions through total equipment inspection
Preparation of regular maintenance standard document and rectifying deterioration
Clarification of relations between equipment accuracy and quality characteristics.
Step 6 Efficiency improvement of maintenance
Improvement of visual control
Improvement of maintainability
Step 7 Implementation of predictive maintenance
Condition monitoring based on simple diagnostic equipment and trend control
Condition base monitoring - deterioration through precision diagnostic equipment and predicting service life.
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