Post on 16-Aug-2015
TPM ACTIVITIES MIXER 2
MOHD RASDAN
GOODYEAR MALAYSIA BERHAD
MALAYSIA MIX#2 TPM
(RELIABILITY IMPROVEMENT)
Mixer 2 TPM Organization Chart - 2015
Yazid YaacobAdvisor
Mohd RasdanTPM Leader
RozaidiQ-Tech Engineer (Mixing)
Sharul NizamTeam Leader C9
SubramaniamTeam Leader C9
Mohd NazriTeam Leader C9
HanafiahBanbury Specialist C10
Wardi MohtarEngineer
Zahari IbrahimEngineer
Nor AziziEng. Specialist
Abdul HalimConstruction Member
Ahmad ZakiBCA Manager
MALAYSIA PLANT - DEFECT CARD BOARD, CLEANING TOOLS BOX AND TPM INFORMATION BOARD
TPM ACTIVITIES (CB DAYBIN)
CARBON BLACK DAYBIN LEAKS ELIMINATED
AND DAILY CHECK LIST SYSTEM DEVELOPED.
Before After
TPM ACTIVITIES (CB DAYBIN)
Before After
DAYBIN CARBON BLACK LEAKS ELIMINATED
AND DAILY CHECK LIST SYSTEM DEVELOPED&IMPLEMENTED AND ALL UNNECESSARY IDLE Eqs REMOVED.
TPM ACTIVITIES ( GENERAL VIEW DAYBIN AREA)
Before After
TPM ACTIVITIES ( DAYBIN SILICA AREA)
Before After
LEAKS SOURCES ELIMINATED WITH RELIABLE
ENGINEERING DESIGN, TPM STANDARDIZATION
&CHECK LIST IMPLEMENTED.
Before After
CHARGE AND DROP DOOR GATE LEAKS REPAIRED AND AREA STANDARDIZED
TPM ACTIVITIES ( MAIN MIXER)
TPM ACTIVITIES ( MAIN MIXER BODY)
Before After
CHARGE AND DROP DOOR GATE LEAKS REPAIRED AND AREA STANDARDIZED
TPM ACTIVITIES (OIL CABINET)
NEW OIL CABINET TO IMPROVE MACHINE RELIABILITY AND TO IMPROVE LEAK
Before After
PROBLEM ANALYZED (SILANIC TANK LEAK)
RESULT AFTER IMPLEMENTATION (BANBURY % PERFECT TURN)
June 2014 -Banbury % Perfect Turn = 69.1% (Before TPM Implementation)
May 2015 – Banbury % Perfect Turn = 84.07% (After TPM Implementation)
RESULT AFTER IMPLEMENTATION (MIXER 2 MACHINE BREAKDOWN 2014/2015)
Initial Cleaning
TPM Level 1
TPM Level 2
RESULT AFTER IMPLEMENTATION (MIXER 2 CB WEIGHING IMPROVEMENT )
CB WEIGHING CONSISTENT AFTER TPM IMPLEMENTATION
RESULT AFTER IMPLEMENTATION (MIXER 2 OIL WEIGHING IMPROVEMENT )
OIL WEIGHING CONSISTENT AFTER TPM IMPLEMENTATION
RESULT AFTER IMPLEMENTATION (MIXER 2 IDLE TIME IMPROVEMENT )
Mixer Daily average Batch increased from 329 / day to 436 /day after TPM
Progress in 8 months
$-
$ 200
$ 400
$ 600
$ 800
$ 1,000
$ 1,200
$ 1,400
$ 1,600
Top 5 Loss CategoryTotal by category
ZERO LOSS ANALYSIS- LOSS STRATIFICATION
-
$ 500
$ 1,000
$ 1,500
$ 2,000
$ 2,500
Top 5 losses by department
IMPACT OF TPM ACTIVITY TO OTHER LOSS CATEGORY
Q3'14 Q4'14 Q1'15
Misc Unknown stop 41 32 28
2.57.5
12.517.522.527.532.537.542.5
$ , K
Q3'14 Q4'14 Q1'15
Rework 46 44 34.57
2.57.5
12.517.522.527.532.537.542.547.5
$ , K
Q3'14 Q4'14 Q1'15
Breakdown Maintenance 33.5 82.6 14.496
5
15
25
35
45
55
65
75
85
$ , K
Reliability Improvement Activities / Spare Part Replacement
OBSERVATION:TPM activity give good impact to other loss category