JIPM-TPM.Sample-Forms-Editing-2

Lubrication Inspection Standard 7 • 3 5 - 10 - (2)

Lubrication Inspection Items Table

No. Inspection contents Judgment Criteria Method Classification
1 Heat generation There should be no abnormal heat generated at Touching Daily
lubrication locations
2 Vibration There should be no abnormal vibration. Touching Daily
3 Noise There should be no abnormal noise generated at Listening Daily
lubrication locations.
4 Name plate There should be an oil name indicator plate. Visual Daily
There should be a color indicator (yellow) on the Visual Daily
5 L/G mount opening oiler, L/G and mount opening
color indicator There should be an oil level line (yellow). Visual Daily
There should be no leakage from the element, Visual Daily
6 Oil level line cover or oil seal.
The oiler should operate normally. Visual Daily
7 Oil leakage from oiler There should be no breakage or dirtiness of the Visual Daily
level gauge or bull's-eye gauge.
8 Oiler operation There should be no leakage from the oil seal. Visual Daily
9 Dirty sighting glass There should be no leakage from the gasket Visual Daily
(mating face).
10 Oil seal leakage There should be no dispersion of the coupling Visual Daily
11 Gasket leakage grease.
There should be no abnormal clogging of the filter. Visual Daily
12 Dispersion of grease The level gauge and the oil surface of the oiler Visual Daily
should be visible.
13 Filter clogging The indicator should be above the MIN level. Visual Daily
14 Oil depletion The indicator should be below the MAX level Visual Daily
There should be no drain oil abnormalities, such Sampling Periodic
15 Below MIN level as discoloration, moisture or metal filings.
The drain oil should not be opaque or cloudy. Sampling Periodic
16 Above MAX level
Periodic
17 Contamination of oil in Periodic
use
Periodic
18 Emulsification of oil in
use Periodic

19 Rust in oil There should be no rust in the drain oil. Sampling Periodic
There should be no abrasion powder in the drain Sampling
20 Metal powder in oil oil. Periodic
There should be no dust or dirt in the drain oil. Sampling
21 Contamination of Periodic
foreign matter in oil Periodic

22 Water in the drain oil There should be no water separated in the drain Sampling Periodic
oil. Sampling
23 Discoloration of oil in There should be no apparent discoloration of the Sampling
use oil in use.
When the foaming in the drain oil does not Sampling
Foaming of the oil in disappear immediately, there should be no Sampling
24 use abnormal foam inside the gauge.
Oil should drip every 30 seconds
25 Drip-type oiler There should be no clogging

26 Clogging of oiler
conduit

27 Oiler ventilation Ensure that the ventilation opening (hole or cut- Sampling
condition out) is open.

© JIPM

Lubrication Oil Mainte

ITEM No. Equipment name Manufacturer Specifications block
Model Tank capacity
Serial No. Pump suction/pres
Date manufactured Pump suction capa

Name of sample oil

Sample No.

Sample oil collection date

Sample oil collection location

Hue ASTM Less than L4

Viscosity cSt40°C 32±10%(28.8 35.2)

Total acid number mgKOH/g Less than 0.25
Moisture ppmV0% Less than 100

Millipore filter mg/100ml Less than 10

Amount of residual oxidation inhibitor % 20 or greater

Rotary pump residual service life 150°C 50 or greater

n-pentane insoluble content

Insoluble content Benzene insoluble content

Resin content

Total base value mgKOH/g

Pass/fail determination Pass/fail Pass/fail

Moisture Hue Total acid Viscosity

140 6 0.25 36
120 5 0.20 34
100 4 0.15 32
3 0.10 30
80 2 0.05 28
60 1 26
40 0 0 24
20 mgKOH/g 22
ASTM cSt40°C
0
ppmV0%

enance Sheet Lubrication Inspection Standard

ssure
acity

Pass/fail Pass/fail Pass/fail Pass/fail Pass/fail Pass/fail

7 • 3 5 - 10 - (3)

© JIPM

List of Protective Articles Used by Work Type

Air Inhalators Gas Masks Safety Gla

Protective Articles Anti-dust goggles
Safety face shield / protective face shield
Name of Work Goggles
Safety glasses
1. Cutting work at milling cutter etc. Anti-dust masks
2. Grinding work at grinders etc. For sulfuric acid/sulfurs
3. Rust removal work For ammonia
4. Sand blasting work For carbon monoxide
5. Gas welding, fusion and heating work For halogen gases
6. Electric welding, fusing work For organic gases
7. Handling of poisonous gas and vapor Air supply mask
8. Handling of poisonous liquid Breathing mask [as used on airlines]
9. Handling of subtances which could cause major Oxygen inhalator
Air inhalator
eye injury, such as acids, alkalines, etc.
10. Handling of poisonous powders or solids
11. Work in which exposed to radiation
12. Work involving radioactive material pollution
13. Work involving dust generation
14. Work under danger of oxygen deprivation
15. " (inside nitrogen) see Note.
16. Work under danger of falling from heights
17. Work under danger of flying or falling objects
18. Live wires, and work near live wires
19. Power outage work
20. Handling of high temperature substances
21. Handling of machines
22. Noise generating work
23. Loading and unloading of freight trucks
24. Work on water or onboard ships

Work Safety Standard 7•3 5 - 11

Safety net No. __/__/__ © JIPM
Radiation dosimeter Prepared on: __/__/__
Film badges Revised on:
Life jackets
Earplugs Note: items inside parenthesis specify work inside equipment such as tanks. Safety belts,Protective Articles etc.
Hanging belt
Escape equipment such as ropes Insulated
Safety belts
Grounding devices / voltage detectors Shoes
Insulated boots
Electricity-proof clothing / insulating mat Protective
Insulated rubber sleeves Gloves
Insulated gloves
Rubber boots Protective
Safety shoes Clothing
Fabric gloves
Heat-proof gloves asses
Solvent-proof rubber gloves
Leather gloves
Protective apron
Protective clothing
Anti-light ray face shield
Anti-light ray glasses

Network Process Table 7 •3 5 - 12

Compressor Periodic Maintenance Network

(Check at point E and stop disassembly of the diaphragm if there are no problems.)

No. Overview of check Check

Verify before starting work: No. Overview of check Check

• Close the COMP and TUR valves • Check the position of oil supply piping
A (floats, dimensions, marks, motion)
• Check for drop in pressure and
replacement status • Check the condition of the couplings (face,
B sludge, hub press-in tab)
• Check that hydraulic pump is stopped
and pressure has dropped • Check the condition of the attachment of
C the vibration meter
• Verification before starting crane work
• Check the suspension of the upper wheel
• Straighten up the maintenance area D (levelness, center of gravity, contacting

Verify before hoisting heavy objects: other objects)

• Check the crane safety equipment

• Perform a safety check of wire ropes
and chain blocks in use

• Check storage space

Prevent anything from falling into the
casing.

• There should be nothing in your pockets

• Be sure to use a cover sheet during
breaks and after completion of the work

• Never place anything on the casing
except tools to be used

Perform the following to prevent oil leaks:

• Directly check all pipes

• Request the manufacturing section to
check the opening and closing and
valves, and recheck

• Check for missing blind flanges and
plugs

• Check for loosening of bolts

• Check the dimensions of gaskets used,
and check for installation of wrong parts

Quality Verification Items
(For those items that currently have a check sheet)

No. Overview of check Check No. Overview of check Check

E • Check the internal condition of the • Worm spacer
upper wheel (dirt, face, floors, O Check after adjustment
labyrinth)
(Recheck wing gap)
• Before disassembly of the BRG
(clearance) P • Check after assembly of thrust
(thrust quantity)
F • Check BRG (oil feed pipes, face,
wear, cracks) • Check before assembly of upper
wheel (sheet surface and sealant)
G • Inspect seals (surface wear, flaws,
crack carbon) Q • Check after servicing coupling (gear
surface)
H • Condition of rotor (dirt, flaws,
deformation) R • Shaft circularity and flaws

• Condition of lower wheel chamber S • Check the press-in tab
(same as E)
T • Check centering
I • Condition of diaphragm (dirt, flaws,
deformation) • Check before connecting coupling
(sliding agent)
J • Check after servicing diaphragm
U • Check before assembly of piping
K • Check after servicing seal (blow)

L • Check after servicing rotor (rivet V • Check after assembly of coupling
flaws or deformation) (same as A)

M • Check after servicing BRG W • During assembly of cover (oil feed
pipe, seal surface, gasket, seal)
N • Check after assembly of BRG
(labyrinth, wing gap, clearance X • Check flushing
bearing)
Y

© JIPM

Periodic Maintenance Inspec

No. Equipment name Inspection results

ction Results Summary Section Subsection Person-in- Periodic Maintenance Report
Manager Manager charge

__________________ Section __/__/__

Measures Future action Other

7•3

5 - 13

© JIPM

Equipment Diagnostic Manual 7 • 3 6 - 1 - (1)

Positioning of Equipment Diagnostic Technology

Positioning of Equipment Diagnostic Technology in Maintenance Management

{1} Prevent deterioration Daily maintenance Inspection Section using the equipment
Cleaning
Early detection of
abnormalities and problems

Normal operation Oiling
Retightenin
Maintenance Clear understanding of
management phenomenon

{2} Measurement of Inspection and examination TBM Specialized maintenance section
deterioration Clear understanding of
cause
{3} Recovery of Inspection and examination CBM
deterioration Preventive maintenance (Equipment Proper repair and
diagnostics) prevention of recurrence
{4} Recovery of fault
Repair

Daily maintenance: Simple servicing of equipment and inspection of problems by
the production division

Normal operation: Correct operation of equipment by the production division

Inspection and examination: Inspection of the condition of deterioration and
presence of problems, and the quantitative measurement thereof /
Equipment diagnostics

Periodic maintenance: Periodic replacement, disassembly and maintenance,
and verification of accuracy

Preventive maintenance: Daily maintenance, and measures for problems
discovered through inspection and examination

Repair: Restoration of failed parts, and prevention of recurrence

Basic System for Equipment Diagnostic Technology

Equipment diagnostic technology
Machine Condition Diagnosis Tech.

Simple diagnostic technology Normal Precision diagnostic technology
Condition Monitoring Tech. Abnormal Condition Analysis Tech.

Used by on-site workers through Implemented by specialists, called
primary health diagnostic technology the Precision Diagnostic Group, by

for equipment means of precision analysis
technology for equipment

Equipment nurse Equipment specialists

© JIPM

Equipment Diagnostic Manual 7 • 3 6 - 1 - (2)

Principle Equipment Diagnostic Technology and Its Main Functions

Classification Diagnostic technology Simple/precision Diagnostic equipment Overview

Rotary machine Diagnosis of bearings, Simple Machine checker Diagnose any unbalance of gears, bearings
diagnostic gears and rotary Precision and rotors caused by large machine vibration.
technology mechanisms

Machine equipment diagnostics • Bearing diagnostic Rotary mechanism Determine the degree, position and cause of
technology diagnostic equipment deterioration of gears, bearings and rotary
mechanisms by means of analyzing the
• Gear diagnostic Machine signal vibration waveform and vibration mode.
technology measuring device
General-purpose Process the vibration and pressure signals so
• Rotary mechanism signal analyzer that they are easy to analyze.
diagnostic technology
Crack monitor As a method for high precision diagnostics,
• Field balance analyze the vibration waveform, since the
technology Ferrography analysis frequency resolving power is extremely high.
equipment Determine the position and cause of
Crack diagnostic Acoustic emission Precision deterioration of the bearings and gears.
Super mega (direct
technology method current high voltage Diagnose the degree and risk of crack
method) development by detecting the sound
Lubrication Ferrography Precision generated when cracks develop.
system diagnostic Simple Automatic insulation
technology Abrasion powder in oil Precision diagnostic equipment Determine the wear on sliding surfaces by the
analysis method (alternating current shape and size of abrasion powder in the
Rotary electrical high voltage method) lubrication oil.
machinery Insulation diagnostic
diagnostic technology Electric coil diagnostic Determine the presence of moisture
technology equipment absorption and pollution of the insulation
material by means of changes in the
Coil diagnostic Precision Rectification insulation resistance over time.
technology characteristics
Electrical equipment diagnostics measurement Determine the degree of deterioration of the
Rectification diagnostics Precision equipment insulation material by the size, phase and
extent of change in the current (current
Control system Motion characteristic Precision Frequency flowing to ground) when a high voltage
diagnostic diagnostics characteristics alternating current is applied.
technology measurement devise
Determine whether there is any loosening of
Waveform diagnostics Precision Thyristor fail tracer the coil due to the insulation material by
(wave memory) applying a large current surge to the coil,
High voltage cable inducing a vibration, and measuring the size
High voltage cable Insulation diagnostics Precision insulation diagnostics and duration of the vibration, and changes in
diagnostic equipment the frequency of the vibration.
technology
Gas in oil analyzer Measure the rectification magnetic flux
Transformer Gas in oil analysis (gas Precision distribution and the contact characteristic of
diagnostic chromatography) the brush at a neutral point, and analyze the
technology cause of the rectification defect by comparing
it with a normal case.

While the control equipment is in operation,
apply a signal that will not affect product
quality, and measure the frequency
characteristics that include the electrical
system and machine system.

Automatically record and replay the waveform
(principally the gate pulse) of each part when
the thryistor control equipment is abnormal.

Apply a high voltage direct current to the
cable, and determine the presence of
deterioration by the presence of time
variations and size of the leakage current.

Determine the presence of insulation
breakdown or local heating by analyzing the
flammable gas component in the oil.

© JIPM

Equipment Diagnostic Manual 7 • 3 6 - 1 - (3)

Purpose and Aims of Equipment Diagnostic Technology

Reason 0 10 Component ratio (%) 80 90 100

{1} Prevention of accidents 20 30 40 50 60 70
{2} Insure and improve equipment reliability 26.4
{3} Extend replacement period
{4} Reduce maintenance costs 20.9
{5} Improve productivity
{6} Cut back inspection and maintenance 11.1
{7} Prevent the disadvantages of production
{8} Promote TPM activities 10.9
{9} Improve product quality
{10} Prevent equipment initial problems 7.7
{11} Improve safety
{12} Conserve resources 5.2
{13} Other
4.2

4.0

2.7

2.7

2.5

0.6

1.0

(N = 478 cases)

Overview of Equipment Diagnostic Technology Basic Course
- Lectures and Demonstrations -

• Program Details
• Actualities of simple diagnostics
Details
• How to promote simple diagnostics

• Vibration measurement and analysis method • Actualities of trend management
(demonstration using a simulator)
Day • How to diagnose machine elements (bearings Day
1 and gears) 2 • Actualities of handling FFT's

• How to set criteria • Actualities of precision diagnostics (centered
on a demonstration)
• Approach to trend management

• How to promote precision diagnostics

• How to diagnose rotary machines

© JIPM

Equipment Diagnostic Manual 7•3 6-2

Predictive Maintenance Selection Flowchart

Is production No
being significantly
hindered when failures Is inspection obligatory Yes
because of statutes?
occur?

Yes

Yes Are there many incidents
of failures?
No

No Is inspection necessary Yes
from the perspective of
Yes Are major stoppages
occurring? safety?

No

No Is inspection necessary Yes
from the perspective of
Yes Are numerous failures
slipping by? preventing pollution?

No

No Is this critical safety Yes
equipment?

Yes Has this equipment
been in use for a long time?
No
(Nearing its service
Yes life?)

Is the backup effective? No No Can it be handled by
breakdown maintenance?

Yes

Is the backup effective? Yes

No

No

Super A rank Super A' rank A Rank B Rank C Rank S Rank

© JIPM

List of Units and Diagnostic Equipment 7•3 6-3

List of Units and Diagnostic Equipment

Category Target equipment Unit Diagnostic equipment Equipment
qty.
Failure Local and overall ventilation Fan and motor bearings Simple and precision diagnostic analyzer
prediction Press Main motor bearing Trend management system (vibration) 511
Conveyor drive unit Reduction gear " 66
Hydraulic press and hydraulic robot Hydraulic pump Pulsation (pressure sensor and FFT) 69
Load wheel and forming Spindle oil Ultrasonic flaw detector 21
Chassis multi-welder Lifter cylinder shaft " 20
Air conditioner for painting equipment Fan shaft " 6
Press main motor Rotor bar breakage FFT analyzer 14
Air conditioner for painting equipment Air supply fan and motor bearing Simple online monitor (vibration) 50
Boots for painting equipment Air supply fan and motor bearing Simple online monitor (vibration) 12
CNC lathe Main shaft FFT analyzer or simple vibration meter 6

484

Dust collector Ball screw Ammeter 484
Heat treatment furnace Main shaft motor Insulation (motor tester) 484
Fan motor bearing Simple vibration meter and precision vibration meter
Failure unit Mixer RC fan motor bearing Simple vibration meter and precision vibration meter 31
discovery Gate cutting machine Load censor 5
Oscillating conveyor Motor reduction gear and vertical shaft Simple vibration meter and precision vibration meter
Various fans Cutter bearing Simple vibration meter and precision vibration meter 24
Automatic lubricator Drive unit bearing Simple vibration meter and FFT analyzer 17
Knockout machine Fan motor bearing Simple vibration meter and precision vibration meter
Six ST casting machines Volume booster In-house developed monitoring equipment 7
Belt conveyor Vibrator Simple vibration meter and FFT analyzer 34
Overhead conveyor Hydraulic motor and pump Vibration monitor
Hydraulic pump Reduction gear and bearing Load sensor 1
Motor driven robot Chain length measurement Length measuring machine data logger 2
Holding furnace for casting Pump Flow rate meter, MD 150 SX 4
Various shafts, bearings and reduction gear FFT analyzer 1
Press Inter-gutter groove Watt meter and power factor meter 32
Crank shaft 1
Connecting rod Ultrasonic flaw detector 6
Intergear connecting bolt 13
Optimal Welding robot Various shafts Precision vibration meter 8
conditions Machine tools Main shaft FFT analyzer 16
Heat treatment furnace RC fan Machine checker 10
Assembly Scott conveyor Drive follower shaft Ultrasonic flaw detector 130
Belt conveyor Reduction gear and bearing Watt meter 30
Molding machine Squeeze pressure Pressure sensor, recorder and FFT analyzer 10
Hydraulic unit operating oil 2
Press and resin forming machine Lubrication unit lubrication oil Millipore and moisture 10
Rod wheel forming machine HIAC and total acid value 2
Gun and trans. coolant ROBOT viscosity 454
Extension of Welding robot Cutting tools Ultrasonic flow rate meter
service life CNC lathe Quenching oil FFT analyzer 200
Heat treatment (quenching) Cutting condition of cutter Quenching cooling power testing machine 235
Continuous cutting machine Chain extension Load sensor
Air supply fan bearing 5
Transport conveyor High-speed spindle Chain automatic measuring device 1
Air conditioner for painting equipment Operating oil and main shaft lubrication Vibration --> Automatic oil supply 24
Internal grinding Grindstone shaft lubrication Oil management machine 8
CNC lathe Gear box lubrication " 7
Grinding machine Operating oil " 484
Transfer machine " 156
Hydraulic unit Compensation for unbalanced condition Winching , Millipore, counter miter and viscosity meter 39
Discharge pressure Precision diagnostic machine 300
Welding conditions
Quality Various fans Reduction gear sun gear Cycle logger When appropriate
assurance Cutting tools load detector Cycle logger 1
Resin forming (bumper forming machine) Ultrasonic flaw detector 3
Chassis stud bolt Pressure input Electric power detector
Press torque pack Cycle logger 20
Machine tools Coolant flow, electric power Load cell 25
Coil feed speed Cycle logger
Pressure press Overall accuracy measurement In-house manufactured logger 2
Slide box 2
High-frequency quenching machine Hook-type cracks 3
Cylinder rod 1
Frameless molding machine Environmental noise Various measuring instruments (standard devises and others)
Cutting tool vibration Laser displacement meter and recorder 3
Safety and Overhead traveling crane Filter Ultrasonic flaw detector 2
environment Press balancer 33
General 52
Noise meter When appropriate
Dust collector FFT analyzer When appropriate
Manometer 31
4715
Total

© JIPM

Equipment Diagnostic Trend 7•3 6-4
Management Sheet

Simple diagnostic Plan code Equipment code Specific code Main specification
Motor rpm: 800 rpm
Trend management sheet Bearing type: 80 mm bearing

LO/value Plant name

Rolling Mill No. 2

Equipment name

Hot Run Table Roll

Initial valueMeasurement conditions: Constant speed loaded operation

Upper level: Speed Lower level: Acceleration

Measurement 1 2 3 4 5 6

H ------

------

V 0.2 0.33 - - - -

0.1 0.05 - - - -

A ------

------

© JIPM

Inspection Report for Predictive Maintenance 7•3 6-5
(Example of Diagnosing Pump Vibration)

Inspection Report for Predictive Maintenance
(Example of Diagnosing Pump Vibration)

Example of Configuration for a Pump Equipment Diagnostic System

(Details of main processing)
• Trend management
• Warning information
• Deterioration measurement
• Precision diagnostics

Trend Management Graph (Daily)

Daily graph: Vibration Equipment repair date 00-00-00

Equipment name: Circulation pump No. 1 Pickup No. 2
Data type 2
Measurement location: Bearing No. 2

1. Average value
2. Maximum value
3. Crest factor
Mode 1 2

3/91 Day Equipment repair date
F1: Recent date display F2: Previous month display F5: Change graph F10: Return to menu

Deterioration Prediction Graph

(Deterioration prediction graph) Pickup No. 2
Mode ACC(O/A)
Equipment name: Circulation pump No. 1

Measurement location: Bearing No. 2

Type Average value

Prediction start date
7/90

Danger level
3,500

Approximation Prediction results

Straight line 6/10//91

Secondary 5/4/91

Index 4/28/91

F1: Operation display F7: Hard copy[up arrow] [down arrow]: Select mode F8: Monthly report graph F10: Return to menu

© JIPM

List of Maintenance Eva

No. Item/Date __/__ __/__ __/__ __/__ No.
1 Number of scheduled inspections 116 108 117 53 A
2 Number of inspections implemented 116 108 115 54 D
3 Inspection implementation rate 100 100 98.3 55 M
4 Number of scheduled examinations 52 52 52 56 M
5 Number of examinations implemented 52 52 52 57 N
6 Examination implementation rate 100 100 100 58 N
7 Number of cases of scheduled maintenance 8 18 5 59 N
8 Number of cases of maintenance implemented 8 11 5 60 S
9 Maintenance implementation rate 100 61.1 100 61 A
10 PM implementation rate 100 96.1 98.9 62 S
11 Number of NG cases 1 2 0 63 P
12 Number of NGs repaired 1 2 0 64 I
13 NG repair rate 100 100 0 65 F
21 Number of project themes registered 1 3 0 66 Q
22 Number of project themes completed 5 0 0 67 E
23 Project theme progress rate 85 100 100 68 E
24 Number of pieces of equipment acquired 0 1 0 71 S
25 Number of failures analyzed 0 0 0 72 S
26 Number of cases of corrective maintenance 2 1 0 73 S
27 Number of standards and one-point lessons 3 0 0 74 N
28 Number of MP information issuances 0 0 0 75 R
31 Preventive maintenance time 76 M
32 Breakdown maintenance time 3350 3830 4970 77 M
33 EDPS processing time 5080 2565 1525 78 P
34 Corrective maintenance time 1465 1085 3980 79 M
35 Manufacturing and construction work time 1530 2060 2075 80 T
36 Production activity time 1880 91 T
37 Spare parts quality control time 490 657 92 N
38 Other time 3635 850 1635 93 N
41 General operating time 90 94 N
42 S/D maintenance time 150 280 101 N
43 Load time 2085 3205 1830 102 N
44 Number of PM unit failures 86400 89280 86400 103 N
45 Number of BM unit failures 104 N
46 Number of To. failures 0 0 0 105 N
47 Number of night-time failures 60354 62002 52293 106 N
48 Number of failures 0.5 hr. or longer 107 P
49 Number of failures 1.0 hr. or longer 0 1 0 108 C
50 Work time to recover failures 8 0 8 109 N
51 Down time (DT) 8 1 8 110 N
52 Operating time 2 0 2 111 N
3 1 3
1 1 1
228 90 245
440 180 245
27715 60213 47604

aluation Indices List of Maintenance Evaluation
Indices
Item/Date __/__ __/__ __/__ __/__

Availability 95.6 97.1 91

Down time rate 0.76 0.3 0.51

MTBF 120.2 1003.6 99.2

MTTR 28.5 90 30.6

Number of minor stoppages 1664 1194 1385

Net operating time 57378 60014 47378

Net operating rate 99.4 99.7 99.5

Standard cycle time 0.95 0.95 0.95

Actual cycle time 0.92 0.94 0.89

Speed operating rate 103.3 101.1 106.7

Performance operating rate 102.7 100.8 106.2

Input quantity 3743110 3844256 3199352

Feed quantity 3720780 3807396 3175592

Quality product rate 99.4 99 99.3

Equipment overall efficiency 97.6 96.9 96

Equipment one hour productivity 3699 3684 3644

Spare parts purchase cost 204890 241680 160850

Spare parts usage cost 189960 319050 63152

Spare parts inventory cost 1536018 1532418 1435138

Number of months of spare parts inventory 8.1 4.8 22.7

Repair cost/unit 0.055 0.063 0.051

Modification parts purchase price 0 136695 156640

Maintenance parts cost/unit 0.055 0.099 0.1

Parts inventory cost/unit 0.034 0.034 0.038

Maintenance work cost/unit 0.094 0.07 0.085

Total maintenance cost/unit 0.183 0.203 0.223

Total number of pieces of equipment 15 15 14

Number of pieces of equipment targeted for PM 12 12 12

Number of specialized maintenance workers 1 1 1

Number of line maintenance workers 111

Number of MMS registered parts 1251 1251 1251 7•3

Number of parts targeted for BM 256 256 256

Number of parts targeted for TBM 36 36 36

Number of parts targeted for CBM1 76 76 76

Number of parts targeted for CBM2 11 11 11

Number of parts targeted for CMB3 000

PM ratio 9.8 9.8 9.8

CBM ratio 70.7 70.7 70.7 7-1

Number of standing spare parts 124 124 124

Number of maintenance spare parts 19 19 19

Number of reserve parts 72 72 72

© JIPM

Equipment overall efficiency Manufacturing Technology

PM implementation rate

2nd half Apr May June July Aug Sep 2nd half Apr May June July Aug Sep 2n
year year ye

Down time rate MTBF (h)

2nd half Apr May June July Aug Sep 2nd half Apr May June July Aug Sep 2n
year year ye

Bar: Number of minor stoppages Total maintenance cost/unit

2nd half Apr May June July Aug Sep 2nd half Apr May June July Aug Sep 2n
year year ye

Number of projects registered and completed Project progress rate Numb

Number of registrations Number of completions Apr May June July Aug Sep 2n
ye

y System Indices Process (__/first half year) Graph of Evaluation Indices

NG repair rate Problem points and countermeasures

nd half Apr May June July Aug Sep
ear

MTTR (min)

nd half Apr May June July Aug Sep
ear

CBM ratio

nd half Apr May June July Aug Sep 7•3
ear

bBearro: fMcoanstehslyo/fLcionrer:eActcivceummualiantteednance

7-2

nd half Apr May June July Aug Sep
ear

© JIPM

Details of Measurement and 7•3 7-3
Evaluation

Details of Measurement and Evaluation

Item Method of calculation Details
Number of failures and Actual value Mean operating time between
minor stoppages failures
MTBF Total operating time / Total failure Failure rate per load time
stoppages count
Failure frequency (Total stoppages count / Total Average repair time
operating time) x 100
Periodic maintenance (Number of cases implemented /
rate Number of planned cases) x 100
Preventive maintenance ((PM cost + CM cost) / (PM cost +
cost ratio CM cost + BM cost)) x 100
MTTR Total repair time / Total repair
count
Maintenance cost Actual value
reduction
Improvement in Actual value
maintenance costs
usage classification

© JIPM

JIPM - TPM® 600 Forms Manual
Sample Formats for the 12 Steps of TPM

7 4 Upgrading Operation and
Maintenance Skills

© JIPM

7 4 Upgrading Operation and Maintenance Skills

1. Education System Chart (1) 1. Education System Chart

2. Upgrading Maintenance Skills

Maintenance Skill Trainer (2)(3)(4) 2. Example of Maintenance Skills
Maintenance Skill Education Education System

Check Level of Understanding (5) 3. Maintenance Skills Education
Curriculum (Beginner)

4. Maintenance Skills Education
Schedule

Correspondence Course (6) 5. Check Level of Understanding
(Mechanical and Electrical)

Skill Evaluation (7) 6. Correspondence Course
Schedule
General Inspection
Implementation 7. Maintenance Skills Evaluation
Table

3. Upgrading Operation Skills

Basic Work Basic Knowledge

Identification (8) 8. Education Items Identification
Identification (9)(10)(11)(12) Table

Check and Approve (12)(13) 9. Mechanism Structural Diagram
Operation Skills Education (14)
10. Machining Principle Diagram
Skill Evaluation
11. One-Point Lesson Sheet

12. Operation Skills Textbook

13. Operation Skills Education
Schedule

14. Operation Skills Evaluation Table

© JIPM

Education System Chart 7•4 1-1

TPM Education System Chart

General employee Group Leader / Subsection Department Manager / Section
Guidance: Plant Manager Manager Manager
Section Manager training meeting
TPM Introductory JIPM guidance training meeting (lodging)
education education

TPM college

Training by Leader training meetings by Section Manager training
theme theme meetings by theme
Trainer
JIPM guidance: Trainer training meeting
education

Guidance: Trainer Guidance: Trainer
Introductory education, how to promote steps Diagnostic technology and IE techniques

Operation Operation Guidance: Group Leaders and Subsection
Leaders
Division skills Guidance: Section Leaders

education Education on operation skills and related
knowledge

Maintenance Guidance: Group Leaders and Subsection Guidance: Instructors
skills Leaders

To acquire knowledge and skills, to (Beginner) (Intermediate) (Advanced)
understand the mechanism of General
equipment one operates on one's own, inspection Foreman Equipment
and to be able to perform simple parts skills
replacement and repair. education maintenance maintenance
One-point lesson
skills basic

processes

Maintenance Basics Guidance: Instructor
Division Based on the equipment maintenance basic curriculum
education
Application Guidance: Instructors Guidance: Instructors

Beginner: Electrical and machine Intermediate: Advanced:
maintenance

© JIPM

Example of Maintenance Skills 7•4 2-2
Education System

Example of Maintenance Skills Education System

Course Level Maintenance worker Operator

Target skill System System Target skill

Advanced Foreman To be able to conduct Equipment Manager course
and higher equipment management
activities

Maintenance Foreman course Maintenance Foreman course

Advanced course

Equipment Production Guidance of
management maintenance subordinates

Intermediate Group To understand the OJT OJT To be able to give
Leader maintenance system and guidance on autonomous
to be able to conduct Technician maintenance.
planned maintenance examination
activities.

To be able to perform Intermediate course Intermediate course To be able to carry out
repairs and restoration. improvements.
Maintenance Examination Repairing Improve- Maintenance Examination Repairing Improve-
To be able to carry out To be able to perform
improvements. minor repairs.

system system failures ment system system failures ment

Beginner General To understand inspection OJT OJT To understand inspection
points and to be able to points and to be able to
take measures. take measures.

To be able to judge normal Beginners' course To be able to judge normal
and abnormal conditions, and abnormal conditions,
and to be able to take Machine Electrical System and and to be able to take
initial measures. basics basics maintenance initial measures.

To be able to carry out To be able to carry out
minor improvements. minor improvements.

Basic New To be able to perform OJT Correspondence To be able to perform
employees work as instructed. courses work as instructed.

To understand safety Basic course To understand safety
standards, and to behave standards and to behave
accordingly. accordingly.

Office work, products, Handling of
manufacturing, common equipment and
sense and knowledge basics of safety

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Maintenance Skills Education 7•4 2-3
Curriculum (Beginner)

Operator Maintenance Skills Education and Training Curriculum
(Beginner's Edition)

Subject Education and Training Item Time Equipment maintenance and
2h basic process

Basic work 1. Properly retighten nuts and bolts
2. Practical skills for appropriate torquing
2h

Drive unit 3. Practical training on methods to set up locking 2h
1. Shaft handling and maintenance points 2h
Lubrication 2. Practical training on driving, shrink fitting and sampling 2h
Pneumatic 3. Types of key matching, and their importance 2h
Hydraulic 4. Techniques of key removal 2h
Electrical 5. Types and standards of meshing 1h
Total 6. Breakage of gears, and maintenance 2h
7. Understanding of chain transmission 1h
8. Understanding of belt transmission 1h
9. Transmissions and reduction gears 1h
1. Functions and types of lubrication oils 1h
2. Testing for excessive and inadequate oiling 2h
3. Understanding of bearing lubrication 1h
1. Types of O-rings 1h
2. Cutout model of pneumatic equipment (3-point set, 3h

cylinders, valves and piping) 2h
1. Hydraulic valves, hydraulic cylinders and operating oil 2h
2. Practical training on attaching high-pressure pipe fittings 2h
1. Electricity basics and safety 2h
2. Switches and control equipment materials 2h
3. Motors 1h
4. Measuring instruments 39h

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Maintenance Skills Education Schedule (Mechanical and Elect

Lectures or practical Education contents Attendees
training
Subject Time Instructor Assigned area Name Schedul Attendance Schedule Atte
required

trical Maintenance) TPM Operation Office Maintenance Skills Education
Date created: __/__/__ Schedule

Education schedule
endance Schedule Attendance Schedule Attendance Schedule Attendance Schedule Attendance Schedule Attendance

7•4

2-4

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Check Level of Understanding 7•4 2-5
(Mechanical and Electrical)

Check Level of Understanding Assigned area

Name

{1} Select the noncontact detector switches from the following list:

A. Microswitch B. Photoelectric switch C. Proximity switch

D. Limit switch E. Ultrasonic switch

{2} To what factors is a thermal relay adjusted?

A. Rated power B. Rated voltage C. Starting current D. Full-load current
{3} Frequent reversing of a motor may cause the molded thermal relay to actuate. What is

this caused by?

A. Heat generated by loosening of the terminal block
B. Heat generated due to the starting current
C. Because the electromagnetic tripping current is set too low
{4} Select from the following the inspection and maintenance points common to direct
current motors and 3-phase induction motors.

A. Bearing management
B. Preventing deterioration of coil insulation
C. Ensuring good rectification conditions
D. Management of fixed terminals
{5} Connect the 3V batteries in the illustration below so that the starting voltage is 12V.

{6} Construct a lamp flasher circuit using the electromagnetic relay "A" contact to light the
lamp when the button switch is pressed. Wire the devices in the illustration below.

Battery Button switch Electromagnetic Lamp
relay

Negative pole Positive pole

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Maintenance Skills Corresponde

Correspondence course OJT or Attendees Circle
details OFF-JT Name
Schedule Attendance Schedule Attendanc
Subject Time Instructor
required

ence Course Schedule Correspondence Course Schedule

Section Subsection Circle
Manager Manager Leader

Section Department

Education schedule

nce Schedule Attendance Schedule Attendance Schedule Attendance Schedule Attendance Schedule Attendance

7•4

2-6

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Maintenance Skills and Education Skill

A Basic work Evaluation items
B Drive unit D Pneumatic
C Lubrication E Hydraulic
F Electrical

Name Name Name

Name Name Name

ls Evaluation Table (Operator) Maintenance Skills Evaluation Table

Level 1 Evaluation level
Level 2 Understands intellectually
Level 3 Can perform work to some extent
Level 4 Can perform work with confidence
Can teach others
Name
Name

Name Name

7•4

2-7

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List of Operation Skills E

____ Circle ____ Section No. 1 ____ Department No. 1

Main category Work classification

1 Materials related 1. Materials disbursement work

2. Transport work

3. Cleaning work

2 Preparation 1. Materials preparation

2. Work instruction sheet confirmation

3. Prepare a frame for inputting finished produ

3 Machine work 1. Operation preparation work

2. Set materials

3. Operation

4. Troubleshooting

5. Sampling verification work

Education Items Education Items Identification Table

Equipment name: __ - __ Time
required
Textbook Page Person-in-charge 15 minutes
No. of education
1A-1 5 Circle Leader

1A-1 6 10 minutes

1A-1 7 15 minutes

1A-1 9 10 minutes

1A-2 3 10 minutes

ucts 1A-1 15 5 minutes

2A-1 5 20 minutes

2A-1 7 5 minutes

2A-1 8~25 120 minutes

2A-1 35 30 minutes

2A-1 39 15 minutes

7•4

3-8

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Mechanism Structural Diagram 7•4 3-9

Equipment name One-Point Lesson No.
Unit names
Division Keypoints / Why

Name Other Work Mechanism structural diagram Basic work
category
classification

Work procedure summary

Section Created Standard
Manager by time Level
Education / / /

record 10 Beginner
min Intermediate
Advanced

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Machining Principle Diagram 7•4 3 - 10

Equipment name Machining Principle Diagram No.
Division
Work name: Explanation of machining Machining principle diagram

No.

Section Created by Date Standard
Manager created time Level
Education
record __ Beginner
min Intermediate
Advanced

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One-Point Lesson Sheet 7•4 3 - 11

Equipment name One-Point Lesson

Division No.

Main Start-up and finishing work Work Transport unit Basic work Method for cleaning
loader/unloader
category classification

Work procedure summary Keypoints / Why

1 Motor unit Grasp cloth firmly and wipe clean.

There should be
no dirt or
overheating.

2 Stage unit Apply absolute alcohol to the cloth and
wipe clean.
There should be
no waste or
deformation.

3 Feed screw unit Apply machine oil to a cloth and There should be
wipe clean.
no deterioration or
dispersion of the
grease.

Verify operation
after cleaning.

Education Section Created Standard Level
record Manager by time

30 Beginner
min Intermediate
Advanced

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Operation Skills Textbook 7•4 3 - 12

Example of Operation Skills Textbook

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Operation Skills Education Schedule 7•4 3 - 13

Operation Skills Education Schedule

No. ___ ___ Circle
Process
A. Difficult
Item B. Regular
C. Simple
No. Work details
Category h hh
Education schedule

Mastery Standards Specific Versatile Knowledge Practical Total 1 month 2 months 3 months
difficulty Textbooks training
Manuals

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Operation Skills Evalu

Circle Section D

Criteria Knowledge Level 1: Understands intellectually Level 2: Can perform work
Subject Skills
Level 3: Can perform work with confidence Level 4: Can teach others

Item

Knowledge
Skill

Knowledge
Skill

Knowledge
Skill

Knowledge
Skill

Knowledge
Skill

Knowledge
Skill

Knowledge
Skill

Knowledge
Skill

Knowledge
Skill

uation Table Operation Skills Evaluation Table

Department

k to some extent
s

Name

7•4

3 - 14

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JIPM - TPM® 600 Forms Manual
Sample Formats for the12 Steps of TPM

8･1 Initial-Phase Product Control

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8･1 Initial-Phase Product Control

Flow

Step Development Production Engineering/Quality Administration Type of Forms
Departments
Assurance Departments (Cost/Purchasing) Departments

Needs Seeds

1. Product Planning Feasibility Study (1) 1 Development Theme
Investigation/Planning 1st DR (2) Plan

2 DR Standards (1st DR
Checksheet)

Development Meeting 3 Diagnosis
(Decision to Start Checksheet
Development)
(3)

2. Basic Design Study of Rough (4) 4 Development
Concept Planning Specifications Plan

Concept
Drawings/Rough
Schedule Plan

Development of
Required New

Technology

2nd DR (5) 5 DR Standards (2nd
and 3rd DR
Checksheets)

Development Meeting 6 Diagnosis
(Decision Regarding Checksheet
Full-Scale Development (6)

of Product)

Determination of Basic
Specifications

3. Detailed Design Detailed Schedule Plan (4)
1st Research Trial/Evaluation
Detailed Design (7) Process Development, (8) (9) 7 Design FMEA Chart
(1st Research Trial Equipment/Process
8 Bottleneck Technology
Specifications) Registration Control

Chart

1st Research Trial 9 Bottleneck Technology
Development Plan
Evaluation of Productivity
and Producing Quality

1st ER (10) 10 ER Standards
(Review of Production (1st ER Checksheet)
*
Problems)

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8･1 Initial-Phase Product Control

Flow

Step Development Production Engineering/Quality Administration Type of Forms
Departments
Assurance Departments (Cost/Purchasing) Departments

Evaluation of Performance
and Reliability

Overall Evaluation of 1st Research Trial Specifications (3rd DR) (5)
TOP Diagnosis (Business Decision)
(11) 11 Diagnosis
Checksheet

Initial-Phase
Production Control
Commencement of Initial- (12) Commencement
Phase Production Control 12 Declaration

Sheet/Conclusion
Authorization Sheet

4. Production Design Design for Mass (7) Detailed Plans for Process (14) 13 Drawing Study
2nd Research Trial/Evaluation Production Methods, Equipment and Feedback Sheet
(13)
(2nd Research Processes 14 Process FMEA Chart
TrialSpecifications)

2nd Research Trial

Evaluation of Productivity and
Producing Quality

2nd ER (15) 15 ER Standards
(2nd ER Checksheet)

Evaluation of
Performance and

Reliability

Overall Evaluation of 2nd Research Trial Specifications (4th DR) (16) 16 DR Standards
(4th DR Checksheet)

TOP Diagnosis (Determination of Equipment Investment and Move to Mass Production) (17) 17 Diagnosis Checksheet

Production Trial Design 18 QA Chart
(Mass Production
Specifications) (18)

5. Production Preparation Establishment of Quality (19) 19 Quality Assurance
Production Trial/Evaluation Assurance Plan (20) System Chart

Preparation of Production 20 Work Standards
Equipment and Processes Sheet

Production Trial
Evaluation of Process
Capability and Producing

Quality

Overall Evaluation of Production Specifications (5th DR) (21) 21 DR Standards
(5th DR Checksheet)

TOP Diagnosis (Decision to Start Mass Production) (22) 22 Diagnosis Checksheet

Mass
Production

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Development Theme Plan 8•1 1-1

Development Theme Plan Group

Created ___/___/___ Revised ___/___/___
___/___/___

Record No: Theme Name: Department
In Charge of Development Division
Reason for Necessity of
Development
Contents and Goals

New Function-Related

Technology

Competitor Status and

Comparison

Tentative Product Sales Volume Unit cost and quantity 3 years after SOP (launch) ¥/unit units/year
Targets
[Estimated market size ¥______million annually]

Cost Base production cost 3 years after SOP ¥/unit

Quality Major performance/reliability targets

Development Period Start of development Target completion of detailed Target SOP

Date:_/_/_ design Date:_/_/_

Date:_/_/_

Period ( ) Period ( ) Period ( ) Period ( ) Period

Development Plan Schedule and

stage

Invested manpower (persons)

Developed equipment (¥, thousands)

Development trial cost

(¥, thousands)

Joint development; with --> ( )

Related divisions;

Anticipated Sales Route

In-house Technology, Equipment

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DR Standards (1st DR Checksheet) 8•1 1-2

1st DR Checksheet (Product Plan)

Product Name DR Member’s Dept.: 　　　　　　　　Name:
No. DR Item
1 Evaluation of Check Point Evaluation (5 Levels) Opinion

goals of theme Suitability of 5 4 3 2 1

2 Grasp of domain strategy Suitable Not Suitable
market trends
Evaluation of 5 4 3 2 1
3 Evaluation of
theme contents environmental Good Bad Effect

Overall Judgment effect

Sales Volume >100 100-50 50-10 10-1 >1

(¥millions/year)

Evaluation of 5 4 3 2 1

market maturity Expanding Contracting

Patent search 5 4 3 2 1

No problem Not yet done

Development 5 4 3 2 1

status of other Undeveloped Finished

companies’ rival

products

Evaluation of 5 4 3 2 1

distinguishability Big difference No difference

from rival

products

Evaluation of 5 4 3 2 1

basic design Good Problem

specifications

Establishment of 5 4 3 2 1

quality targets Established Not yet

Establishment of Est. incl. Cost Not yet

cost targets sales price only

Evaluation of 5 4 3 2 1

schedule plan Good Problem

Necessary 5 4 3 2 1

manpower plan Good No plan yet.

Necessary 5 4 3 2 1

equipment plan Good No plan yet.

Evaluation of 5 4 3 2 1

technical Prototype made. Not made yet.

feasibility

Use of in-house Adequate Partial Unrelated

know-how use. use.

Proceed to next OK OK with Not OK

step conditions

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Diagnosis Checksheet 8•1 1-3

Diagnosis Checksheet

Date of Diagnosis___/___/___
Diagnosed By________________

At stage when product planning is complete.
Product: Newly developed version of an existing product

Points Diagnosed: The product concept 10 years from now is clear, and the tentative targets for QCD
have been set.

Theme Name:______________________________________________

Development Department Name:___________________________

Results of Diagnosis (Please circle the appropriate answer. Circle the middle answer if unsure).

Evaluation Item 5 4 3 2 1 Evaluation Comments

1 Product differentiation Major Some No diff.
(compared to other

companies)

2 Match with customer Adequate Right Direction Doubtful
needs

3 Target cost level Major Some No diff.
(% reduced from current (30% +) (10-20%)

cost level)

4 Timing for completion of Ahead of Meeting Behind
development of functions customer customer

needs. needs.

5 Sales volume after 3 years >100 100-50 50-10 10-1 >1
(¥ millions/year)

6 Development status at Undevel- Sales with in Mass prod.
other companies oped. 3 years. stage.

7 Effect on current Can use Can use Need new.
equipment as is. with

modification.

Overall Judgment and Comments OK Not OK
Proceed to next step (basic design):

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Master Schedule of Initial-Phase Pro

Schedule of Activities Prior to First Half First Half [of Fiscal Year]

Product Name /4 5 6 7 8
Dept. (Person in Charge)

E

M
L

Research

oduct Control Theme Activities Development Plan

Second Half 8•1

9 10 11 12 /1 2 3 Beyond Second Half 2-4

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