JIshu Hozen is a Japanese word that means Autonomous Maintainance. In this article, I will discuss, What is Jishu Hozen and the 7 steps of Jishu Hozen.
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1 Jishu Hozen
JIshu Hozen is a Japanese word that teaches us to maintain the machine and tools by the operator, not the maintenance person. It is a methodology that focuses on empowering operators and frontline employees to take ownership of the maintenance and care of their equipment and machines.
Jishu Hozen is also known as the JH pillar of TPM(Total Productive Maintenance). The goal of the Jishu Hozen is to improve overall equipment effectiveness (OEE). It can be done by preventing equipment breakdowns, reducing defects, and maximizing equipment efficiency.
Jishu Hozen also promotes “I operate I maintain, rather than I operate you maintain”. It means that the machine or the tool used by the person maintains on his own rather than the person assigned for the task.
The implementation of Jishu Hozen requires close collaboration between operators, maintenance personnel, and management. It aims to create a sense of ownership, responsibility, and empowerment among operators, leading to improved equipment reliability, productivity, and overall organizational efficiency.
Objectives of Jishu Hozen
The objective of Jishu Hozen is to improve the maintaining power are-
* The primary objective of Jishu Hozen is the equipment’s reliability. That means eliminating equipment breakdowns and minimizing unplanned downtime.
* Jishu Hozen focusing on maximizing OEE.
* Jishu Hozen aims to reduce defects and product variations caused by equipment issues.
* It promotes skill development among operators.
* It promotes a sense of ownership, empowerment, and responsibility among the employees.
How to implement JIshu Hozen?
Jishu Hozen or Autonomous Maintainance has several steps to implement. It requires collaboration between operators, maintenance personnel, and management. Some of the steps are-
* The top authorities must understand the benefits and importance of Jishu Hozen.
* Establish a team for planning and overseeing the implementation of Jishu Hozen.
* Operators should have the skill to operate the machine perfectly for better production.
* Develop standard procedures and checklists.
* Conduct training sessions to educate operators and maintenance personnel on the principles and techniques of Jishu Hozen.
* Implement cleaning and inspection activities with equipment ownership and autonomy.
Remember, the implementation process may vary based on the specific needs of your organization. It is essential to adapt it to your unique requirements. Regular communication, training, and ongoing support are crucial for successful implementation and sustained benefits from Jishu Hozen.
Jishu Hozen meaning
Jishu Hozen is the concept in the field of Total Productive Maintenance. The word Jishu Hozen is taken from Japan and its original meaning is Autonomous Maintainance.
This methodology, It empowers employees to take responsibility for the care and upkeep of their equipment, ensuring its optimal performance and minimizing downtime.
Jishu Hozen is a very good concept for increasing the productivity of manufacturing. It ensures all the employees keep and clean their machines on their own.
JIshu Hozen Steps
Jishu Hozen’s concept is based on 7 steps. These steps are indicating the best practice and performance for the employees. These steps are –
- Initial cleaning.
- Countermeasure Implementation.
- General Inspection.
- Autonomous Inspection.
- Autonomous Control.
- Professional Maintenance.
1. Initial Cleaning-
In Jishu Hozen, Initial Cleaning is referred to as the first step. In this step, the operators thoroughly clean the equipment and its surroundings. The purpose of this step is to create a clean and safe working environment for the equipment and operators.
During the initial cleaning, operators or workers remove dirt, dust, and any other contaminants that may have accumulated on or around the equipment.
They clean various parts, surfaces, and components of the equipment to ensure that they are free from any substances. The cleaning process may involve using brushes, cloths, compressed air, vacuum cleaners, or other appropriate tools.
It helps operators become familiar with the equipment and its condition, making it easier to identify the tasks.
It promotes a sense of ownership, cleanliness, and attention to detail among operators.
2. Countermeasure Implementation-
This is the second process where operators and maintenance personnel identify and address the root causes of equipment abnormalities and defects.
Making adjustments to the equipment to eliminate or reduce the cause of the problem. Modifying the work process.
Providing additional training to operators and maintenance personnel to increase their knowledge and skills in addressing specific issues.
Adjusting or improving maintenance practices to prevent issues. Implementing additional quality control checks or inspections to detect and prevent defects.
The countermeasure implementation step emphasizes the importance of addressing the root causes rather than just addressing symptoms or temporary fixes.
3. General Inspection-
This is the third step of Jishu Hozen. In this step, operators conduct routine inspections to identify abnormalities in the equipment. It helps operators detect any deviations from normal operating conditions.
During a general inspection, operators use their senses (sight, sound, touch) to observe and assess the equipment. The purpose of the general inspection is to identify early warning signs of potential problems.
By conducting regular inspections, operators can detect issues. After detecting the issues they can use their skill to fix them,
During the inspection, operators may refer to standardized checklists or guidelines to ensure that they cover all the relevant areas of the equipment.
It empowers operators to be vigilant and proactive in monitoring the condition of the equipment they work with.
4. Autonomous Inspection-
Autonomous Inspection is the fourth process of Jishu Hozen. In this step, the inspector inspects the wear and tear of the machines, damage, or deterioration in the equipment. It is a more in-depth inspection.
Autonomous inspections are operated by operators. They have specific training.
During the process, operators use specific inspection tools and instruments such as gauges, calipers, vibration meters, thermometers, or other measuring devices to gather precise data on the condition of the equipment.
The purpose of the autonomous inspection is to detect any signs of abnormalities that may not be visible during inspections.
Through the process, operators can monitor critical parameters, such as wear levels, lubrication conditions, alignment, temperature, or vibration patterns.
If any abnormalities or deviations from the desired condition are detected during the inspection, operators document their findings, report them to maintenance personnel or relevant teams, and take appropriate action as per established procedures.
This is the fifth process of Jishu Hozen, which refers to the implementation of standardized procedures for maintenance activities. It aims to ensure consistency, efficiency, and effectiveness.
Standardization plays a crucial role in Jishu Hozen by establishing clear and uniform practices for equipment maintenance. It makes the operators more skillful in their job.
Standardization involves developing step-by-step procedures for routine maintenance tasks, inspections, cleaning, lubrication, and other activities.
Checklist all the information you gather from the inspection. It will help to conduct the work more efficiently. The creation of guidelines and reference materials that provide additional information, best practices, and troubleshooting tips.
Standardization involves documenting the standardized procedures, checklists, and guidelines in a clear and accessible format.
The purpose of standardization in Jishu Hozen is to promote consistency, reduce errors, and enhance the overall quality and reliability of maintenance activities.
6. Autonomous Control-
This Autonomous control step in Jishu Hozen refers to empowering operators to deal with the equipment properly and maintain them. Autonomous control encourages operators to take ownership and actively participate in the care and maintenance of the equipment.
Operators need to be trained to perform routine maintenance tasks such as lubrication, cleaning, tightening, or basic inspections. They can make minor adjustments within predefined limits to optimize equipment performance.
Operators actively monitor the equipment during operation. If there is a need to take action, they should be well-trained to do so.
Operators need to maintain records of their maintenance activities. These records serve as valuable information for tracking the equipment’s history, identifying trends, and providing insights for continuous improvement.
7. Professional Maintainance-
This is a very important step for Jishu Hozen. In this process, the collaboration between operators and maintenance person ensures the effective and timely resolution of equipment issues that are beyond the scope of operators’ autonomous control.
While operators are empowered to perform routine maintenance activities and make minor adjustments, professional maintenance recognizes that there are instances where the expertise and technical knowledge of maintenance personnel are required to handle more advanced maintenance tasks.
Operators must report abnormalities beyond their autonomous control to the maintenance team. Maintenance professionals are responsible for conducting in-depth troubleshooting and analysis of equipment issues that require specialized knowledge and skills.
Professional maintenance persons are responsible for performing complex repairs, major adjustments, overhauls, or other significant maintenance tasks. They provide feedback and recommendations to operators based on their analysis of equipment issues.
Professional maintenance in Jishu Hozen ensures that equipment issues are appropriately addressed by engaging the expertise of maintenance professionals when needed.