The challenge to the special award

1.About Visual Control

20 Apr. 2017
JMA Consultants Inc.
TPM Consulting Company
TPM Consultant
Kazuyuki Sugawara
TPM

URL http://jmac.jp 2017 JMA Consultants Inc. TPM Company

 A Typical Jishu-Hozen Programme for Process Industries
Step Name
1 Initial cleaning (cleaning
is inspection)
2 Countermeasures for
Contamination sources
and hard-to-access areas
3 Provisional standards
4 General equipment
inspection
5 Total process inspection
6 Systematisation
7 Full self-management
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Activities
Eliminate dust and dirt from main body of equipment
Identify faults, sources of contamination, hard-to-access areas, sources of quality
defects, etc.
Remove unnecessary or obsolete equipment and simplify remaining equipment
Reduce time required for all sorts of tasks by eliminating or containing sources
of dust, dirt or other contamination, and improving places that are hard to clean,
lubricate, tighten or check
Formulate provisional action standards to enable cleaning, lubricating, tightening
and checking to be sustained dependably with minimal time and effort
Improve inspection efficiency by introducing visual controls
Train operators in inspection procedures using inspection manuals
Restore individual equipment units to their ideal state through comprehensive
inspection and restoration
Make the equipment easier to inspect and introduce comprehensive Visual
control
Improve the reliability of processes by developing process-competent operators
thoroughly trained in process performance, operation, adjustment, and corrective
action
Integrate provisional cleaning and inspection standards for each unit with
periodic inspection and replacement standards for each area or process in order
to eliminate duplication and ensure all necessary checks are done
Ensure that Jishu Hozen is reliably performed, and assure Quality-Hozen and
safety by making system flow charts and standards clear
Improve changeovers and reduce work-in-progress inventories
Establish self-managed systems for controlling workplace flow, spare parts,
tools, work in progress, documentation, etc.
Develop activities in line with company and factory policies and objectives and
make improvement a routine part of the job, reducing costs by driving out waste
2017 JMA Consultants Inc. TPM Company
 1.About visual control
The control object is judged abnormal by oneself, abnormal
own is worked a human by pressure and says system that is
performed by sure action and announcement of abnormal
measures for a human.

URL http://jmac.jp 2017 JMA Consultants Inc. TPM Company

 This is the rate of the five senses of the animal which is.
By the way, what animal will it be?

smell
hearing touch 2 taste touch
taste 5 smell
7 3 1
10 40
hearing
15
sight
sight
87
30

Human Dog
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 Abnormal one.

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 Visual control

In the Shinkansen

vacant occupied

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 Visual control
in the parking lot

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 Visual control and visual
indicator is different

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EX. Visual control and visual indicator is different.

upper upper
upper upper

Visual Rubber
lower
indicater lower ring Visual contro

I know some thing. I know that a proper quantity is injected.

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 Compare of Good or not good color
Not good
Abnormal Normal
Dangerous
Kgf/cm2
- Normal management width is wide
so that abnormality is normalized.
- Setting of normal and abnormal
management width is performed by
hunch and experience of the past.
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Good
Abnormal Normal
Dangerous
Kgf/cm2
* Normal and an abnormal
judgment standard are quantified,
and management width is made a
color precisely.
* Setting of normal and abnormal
management width is performed
for a logical and experiment.
2017 JMA Consultants Inc. TPM Company


It becomes normal when the abnormal

continues.

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 Do not need to climb.

Before To climb the ladder and After Easy to inspect.

inspect motor.
a stethoscope stick Microphone

I can hear it in the

same way as
inspection
by using of a
stethoscope stick

Idemitsu Kosan Chiba Refinery

URL http://jmac.jp 2017 JMA Consultants Inc. TPM Company

 Check transportation grime on ground
System of Kaizen
After
Befor
e

Plastic Wire
board

Grime

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 Become easy to see.

The chain tensioner establishment.

The inside comes to seem to paint black well.

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 Easy to judge

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 Easy for inspection by visual control.
Where is the inspection-point?

It isn't necessary to remember if numbering.

What is the inspection part?

The circulation fan

part Check Item Judgment

Motor Generation of heat. No heat. Yoshi!

V-belt Moving No moving. Yoshi! V-bel tension inspection

Fan Vibration No vibration. Yoshi!

Bearing Noise No noise. Yoshi!

URL http://jmac.jp 2017 JMA Consultants Inc. TPM Company