The challenge to the special award

1.About Visual Control

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

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 A Typical Jishu-Hozen Programme for Process Industries
Step Name Activities
1 Initial cleaning (cleaning Eliminate dust and dirt from main body of equipment
is inspection) Identify faults, sources of contamination, hard-to-access areas, sources of quality
defects, etc.
Remove unnecessary or obsolete equipment and simplify remaining equipment
2 Countermeasures for Reduce time required for all sorts of tasks by eliminating or containing sources
Contamination sources of dust, dirt or other contamination, and improving places that are hard to clean,
lubricate, tighten or check
and hard-to-access areas
3 Provisional standards 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

4 General equipment Train operators in inspection procedures using inspection manuals

inspection Restore individual equipment units to their ideal state through comprehensive
inspection and restoration
Make the equipment easier to inspect and introduce comprehensive Visual
control
5 Total process inspection 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
6 Systematisation 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.
7 Full self-management 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

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 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.

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 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 Good

Abnormal Normal Abnormal Normal

Dangerous Dangerous

Kgf/cm2 Kgf/cm2

* Normal and an abnormal

- Normal management width is wide judgment standard are quantified,
so that abnormality is normalized. and management width is made a
- Setting of normal and abnormal color precisely.
management width is performed by * Setting of normal and abnormal
hunch and experience of the past. management width is performed
for a logical and experiment.
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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

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 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!

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