Losses due to scarce cleaning

1
Losses due to scarce cleaning
Example
Forced deterioration In presence of dirt and
scatterings, it is difficult to check and detect
loosenings, cracks, clearance, lack of oil, with
subsequent continuous forced deterioration
2
Losses due to scarce cleaning
Breakdown The infiltration of foreign bodies in
rotating parts, in sliding parts, in pneumatic
and hydraulic systems, in electric and control
systems, in sensors, etc. generates
malfunctionings and breakdowns due to use,
obstruction, resistance and feeding of inadequate
power
3
Key points initial cleaning

• Initial cleaning is the first activity of
  Autonomous Management
• Safety must be the top priority
• Operators must become aware of the fact that
  keeping the machine clean is one of their jobs
• All the dirt that has accumulated over the years
  must be completely removed
• Lids and safety panels must be opened and
  internal parts of the machine must be cleaned,
  too
• The auxiliary parts of the machine must also be
  cleaned
• All the unnecessary objects close to the machine
  must be removed.

4
Initial cleaning - Familiarize with the machine
HUH? I didn't know there was a lubricator there!!
This first level of awareness is the opportunity
to start a training process
5
Initial Cleaning - Discover anomalies
Cleaning means inspecting
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Example

Evident
Hidden
What is happening under all this dirt ?
During cleaning activities, a crack has been
identified in the base of Banbury mixer number 1.
If the crack had been ignored, the base would
have broken and it would have taken two weeks to
replace it.
7
Initial Cleaning - Identify contamination sources
Start to understand the importance of keeping
everything clean
8
Continuous inspection and taggingPut a tag where
there is something wrong
Tagging It highlights improvement opportunities
of the machine It is an opportunity for
operators' training
9
Continuous inspection and taggingExample of
anomalies
Project no.
Machine
Type of anomaly
Possible intervention
Found
Done
Lack of lids, safety panes
Difficult inspection of internal areas
Lack of valves and pressure gauges
Indication of the correct pressure
Hard-to-clean places
Fluid leaks(water - air - oil - steam)
10
Continuous inspection and taggingExample of
anomalies- 2
Type of anomaly
Possible intervention
Found
Done
Lack of stickers indicating motor temperature
Thermoresistant stickers
Direction of belt and chain rotation
Acrylic material window. Belt model and series
number
Lack of transparent inspection doors
Lack of different blocking reference systems
Misaligned chains, joints
Lack of identification of open / closed valves
Difficulty in lubricating and in carrying out
controls
Does the quantity of oil belong to the
appropriate range?
11
Continuous inspection and taggingThe use of tags
Fill in the tag and hang it where the anomaly
has been detected. If the anomaly appears on a
mobile part,the tag should be placed as close as
possible.
Tagging is a continuous action!
Always keep the original!
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Continuous TaggingTagging rules
1 - Detect machine anomalies (of any type, even
those that seem insignificant).
3 - Attach the tag baside the detect or where the
breakdown was found. If the anomaly is found on a
moving part of the machine, attach it as close as
possible.
4 - Record the data on the tag on the register
book. Make sure the number, description of the
anomaly, and its position on the machine are the
same on the tag and in the register book.
2 - Fill in the tag. Clearly insert the data that
is required (see example).
Tagging is a continuous operation every time you
find an anomaly on the machine, you have to tag
it!