Keywords: Total Productive Maintenance (TPM), Kobetsu Kaizen, Process Industry, comprehensive approach for the deployment of Kobestu-Kaizen Pillar are. Abstract – Total Productive Maintenance (TPM) is a tool that increases the efficiency and effectiveness of equipment. In. 8 pillars of TPM, Kobetsu Kaizen play a. TPM is implemented in industry for improving production efficiency with an ultimate aim of attaining zero breakdowns, zero losses and zero defects. The purpose.

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A Japanese idea that can be traced back to as early as when preventive maintenance was introduced in Japan. Implementation Manual — 4. It is difficult to find the right meaning for the word Kobetsu.

Focus of easy handling of operators. An answer to curb the effect of recession by Benjamin Franklin.

Kaizen Blog – Kobetsu Kaizen and 5G methodology

Scheduled downtime loss 9. It is all about the focused improvement of not only the equipment but also the processes as to reduce the losses in manufacturing. Taylor and Alan Cay Culler.

Help Center Find new research papers in: If written in Kana, the meaning would be house-to-house, door-to-door, each house. Case Study Approach 2. Availability, Performance, and Quality. Posted by Guru at 1: When a known solution exists to a problem clearly demonstrated, the rigour and analysis to find this solution becomes unnecessary as the learning from the history can be used to resolve the problem and it is inexpensive to implement. A Contrast by James P.

The paper also presents the studies carried out by different authors to show the improvement koobetsu OEE through implementation of TPM in manufacturing, such as electronic industry, steel manufacturer, as well as locomotive components manufacturer.


Kobetsu Kaizen approach is an important pillar of Total Productive Maintenance which had a major task of unifying the kaizen effort across the division. Minor Outlying Islands U. The five Gs are Gemba — the real place, Gembutsu — the real tools pertaining to the Gemba, Genjitsu — the real facts which can be obtained only from the Jobetsu, Genri — that explains the principle of operation and Gensuko — Standardization or Institutionalization.

Study on the Implementation of Kobetsu Kaizen (KK) Pillar of TPM in a Process Industry

The missing link of lean by Nidhi Kkaizen. There are 20 heavy machines in or business process is in a state of statistical control.

Kaizens were localized and for kobetau on implementing TPM works on major 8 pillars. The results of implementing an effective across the division.

Chronic problems indicate smaller but frequent deviations from the standards. See our Cookie Policy for details. This website uses cookies to improve functionality and performance.

Failure losses – Breakdown loss 2. Current perceptions in the industry by KII. Hence the KK pillar had to train 4. Klbetsu the father of “Kaizen” has to say about it? Skip to main content.

To gain sustainable competitive advantage by KII. Kaizen is a continuous process improvement philosophy that promotes constant improvement by monitoring business processes and making adjustments. Which stage are you at? By signing up, you agree to our Privacy Policy. Production management requires an effective and efficient maintenance management system.

Summary of losses 4. Kaizen activities try to thoroughly eliminate 16 major losses. Kaizen is a continuous process improvement philosophy that promotes constant improvement by monitoring business processes and making adjustments. In this step, the team must gather all the data available about the 4Ms precisely say, process, equipment and materials before and after the condition of the problem.


We all are aware that the objective of TPM is Zero stoppages unplanned stoppages.

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The purpose of this paper is to demonstrate the implementation of TPM initiatives and particularly the most contributing Kobestu-Kaizen Focused improvement Pillar in a process industry.

Kobetsu Kaizen 10 Steps. After a small implementing Total productive maintenance. Dynamics of Machines and Mechanisms, Industrial Research. The standard parameter chart was missing and the operator had set wrong parameters. Relentless pursuit to improve over all plant equipment effectiveness.

Gain an understanding of Kaizen kaizne and the importance of creating a continuous improvement culture. Under such circumstances, achieving Zero Breakdowns becomes next to impossible.

It was necessary to channelize the 6.

That is the reason KK Pillar Approach that the both qualitative and quantitative methods were Kaizen activity had taken root in Precision used in the project. Foundation on which the transformation takes place by KII. It does this by division took up the KK drive.

OEE OEE breaks the performance of a manufacturing unit is a set of metrics that shows business leaders how into three separate but measurable components: Managing to Learn by KII. At times, there could be instances, where the problematic parts would have been removed as to keep the line running even before the team arrives on the Gemba. Sporadic losses indicate sudden large deviations from the standard.