Introduction to Kobetsu KAIZEN™ and Autonomous Maintenance

Kobetsu KAIZEN™: Ever since Sensei Imai San had published the book Kaizen, it has become a common phrase in the Industry circle where Business Excellence or Operational Excellence is practised. As it got popularized, KAIZEN™ was perceived in various aspects among various levels. It is Change for better for some, suggestion scheme for some. However, few knew that Kaizen is an umbrella where every tool of continuous improvement initiative takes shelter.

Kobetsu KAIZEN™, roughly translated as Focussed Improvement. The objective of this pillar is to improve the efficiency and effectiveness of the maintenance system.

In this program, attendees will be exposed to the 16 types of losses that happen in the manufacturing industry, how to do loss-tree-analysis, how to choose a project, project organization and conduct the project using PDCA-SDCA cycles. Attendees will be made aware of sporadic losses and chronic losses and how to handle chronic losses.

Autonomous Maintenance: Sensei Masaaki Imai says, “Everything on the Gemba is destined to deteriorate if left alone.” Courtesy, lockdown due to Covid-19 crisis, some of us had to leave equipment in our facilities unattended for some time. The lockdown will be lifted soon, and Operations will resume. As this unattended equipment resume, one might experience unexpected breakdowns. With pressures mounting from all corners, one has to be flexible and swift enough to restore the equipment performance.

This program is about developing the capabilities of operators in sustaining the healthy conditions of the equipment. This initiative is called Autonomous Maintenance (Jishu Hozen). All these happen by involving them in doing activities like Cleaning, Oiling, Tightening & Inspection but in a structured manner.

Autonomous Maintenance is one of the building blocks in any TPM initiative. The objective of this program is to develop Equipment & Process Competent operators. Organizations who have practised Autonomous Maintenance effectively, have reaped benefits such as maximized equipment performance, reduced unplanned stoppages, reduced accidents, reduced defects etc.