Post on 15-Apr-2017
Journey of
TPM Salalah Implementation
TPM preparation phase .
TPM Kickoff .
TPM progress in first phase .
Results .
Content
TPM preparation phase .
TPM Kickoff .
TPM progress in first phase .
Results .
Content
1. Declaration by top Management.
2. Awareness & Training (5S & Pilot on Model Machines)
3. Formation of TPM Organization / Promotion team / Logo
4. Setting basic TPM targets.
5. Create TPM Master plan.
TPM Preparation Phase Steps
• TPM Steering Committee Monthly Review Meeting.
• Regular Site Reviews to the People & Equipment.
• Demanding the Results.
TPM Declaration by Top Management & Their Commitment
Safety
Quality
Productivity
Awareness & Training ( 5S and MMM)
RTG#37
EH#08
TT#107
QC SPR #26
RS#05
QC#09
Selected Managers Model Machines for TPM Preparation Phase:
About 70 individuals combined from Engineering , Operation & HSE were
selected to manage and lead Manager Model Machines.
Awareness & Training ( 5S and MMM)
1st
Nov 12
2nd
March 13
3rd
July 13
4th
Aug 13
Kick off
17th Sept 13
Pe
rfo
rman
ce
• Complete Step 0 • Start Step 1
• Complete Step 1 • Start Step 2
• Complete Step 2 • Start step 3
• Complete Step 3 • Step 3, 4 & 5 of
Preparation Phase
TPM Preparation Phase Workshops
Kaizens Abnormalities Sheet
One Point Lesson Breakdowns Analysis
TPM MMM – Key Activities
Training Modules
Tentative Standard Sheet
MMM Results
No. Model Machine KPI
(AVG / Month)
Baseline
(Before TPM Stared)
Results
(After TPM Started) Result %
1 EH 08 BD 10 2 -80%
MTBF 38 291 666%
2 QC Spreader 26 BD 4 1 -75%
MTBF 183 300 64%
3 RTG 37 BD 7 1 -86%
MTBF 80 404 405%
4 TT 107 BD 2 0 -100%
MTBF 380 400 5%
5 QC 09 BD 14 8 -43%
MTBF 38 73 92%
6 RS 05 BD 4 2 -50%
MTBF 66 135 105%
Key Performance Indicators
AVG Breakdowns
Reduction is 72 %
AVG Increase Mean Time Between
Failures is 223 %
MMM Results
High People Engagement !!
TPM Logo, Policy, Target & Master plan
Logo, Policy , Target &
Master plan
TPM preparation phase .
TPM Kickoff .
TPM progress in first phase .
Results .
Content
TPM Kick Off on 17th of Sept 2013
14
MMM Leaders Ahmed Akaak, Acting
CEO Incense Ignition by SMT Abdul Wadood, TPM Consultant
Erik Sasz, GM CT Operation Naif Al-Awaid,
GM Shared Service Centre
Amr Khalifa, GM Tech Asset Management, AME
APMT Region
Musallam Tabook, Labor Union Chairman
TPM Kick Off on 17th of Sept 2013
15
Manger Model Machines Exhibition in Site
TPM preparation phase .
TPM Kickoff .
TPM progress in first phase .
Results .
Content
TPM Sub-Committees Review
AM Teams Training
Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar
1
1.1
1.2
1.3
1.4
2
2.1
2.2
2.3
2.4 Shift 4
3
3.1
3.2
3.3
3.4
Plan Actual
Shift 3
Shift 4
Implement Step 3 ( Tentative Standard )
Shift 1
Shift 2
Implement Step 2 ( Countermeasure of SOC & HAT )
Shift 1
Shift 2
Shift 3
Shift 4
Shift 3
Shift 2
Autonomous Maintenance Master Plan - First Phase
2015
Shift 1
S.No Activity2013 2014
Implement Step 0 & Step 1 ( Initial Cleaning )
AM Master plan and Activity Glimpses
AM Abnormalities Dashboard
Dept. TeamsAreas /
Equipment
Operational
Abnormalities
Identified
Technical
Abnormalities
Identified
Total
Abnormalities
Identified
Operational
Abnormalities
Rectified
Technical
Abnormalities
Rectified
Total
Abnormalities
Rectified
% of OPS
Abnormalities
Rectified
% of TECH
Abnormalities
Rectified
Quay Side 504 860 1364 476 614 1090 94% 71%
Yard Side 280 501 781 248 306 554 89% 61%
Quay Side 578 766 1344 502 686 1188 87% 90%
Yard Side 270 255 525 249 196 445 92% 77%
Quay Side 652 722 1374 525 492 1017 81% 68%
Yard Side 126 392 518 106 287 393 84% 73%
Quay Side 296 612 908 256 451 707 86% 74%
Yard Side 149 352 501 136 322 458 91% 91%
MHC 03 GCT Team41 24 80 104 20 50 70 83% 63%
RS 04 GCT Team43 37 171 208 37 53 90 100% 31%
MHC01 GCT Team44 10 76 86 1 1 2 10% 1%
Marine Marine Team42 Tug Boat -Hasik 179 145 324 179 143 322 100% 99%
GCT
Shift 1
Shift 2
Shift 3
Shift 4
CT
AM Step 2 Training & Activity Status :
39 40 39 40
158
43 43 43 43
172
020406080
100120140160
1 2 3 4 Total
Shift
Total Members & Trained / Shift
Total Trained
Total Members
Step 2 Training completed for
92% AM Teams
AM Step 2:Source of Contamination and Hard to Access Activities:
Total # of 315 Source of contamination and 125
Hard to Accesses Identified by AM in All
equipment's
AM Step 2: One Point Lesson Activities:
Number of 201 OPL reported by
the teams
AM Step 2: Kaizen Implementation Status
Kaizen is our approach to Continuous Improvement !!!
104 Kaizen Idea 63 implemented and 41 in
progress
AM STEP 2: Visual management in the Machines
Zone (Where) Illustration Work Type Sr. No. Critical Parts (Which)
Qty of
Ctrictical
Parts.
C L R I Standards (What should be) MethodTools and
handling
Time
(min)Cycle Who
During
operation
During
stoppage
Impact (Breakdown,
Accident, Cost)
Electrical 1 Motor encoder 2 x x x Clean and tight visual & physical N I 40 M Engg b Breakdown
Electrical x x x Clean and Not damage. visual & physical N I 20 M Engg bB/A/C
OPS x Clean and Not damage. visual N 5 D OPS bB/A/C
Electrical x x Working Well visual I 20 M Engg bA/C
OPS x Working Well visual N 5 D OPS Forman bA/C
Electrical 4 Motor Terminal conection 2 x x x Tight and Not Damage. visual & physical N I 40 3M Engg bB
Electrical 5 Motor insulation value check 2 x x Check with Megger 50 to 100 mmegaohms visual I 80 M Engg bB
Electrical 6 Motor lubrication 2 x x x x Change old grease with new one. visual & physical N I 30 M Engg bB
Mechanical 7Gear box oil level
2 x x Clean and in max level visual I 2 M Engg bB
Mechanical 8Gear box mounting bolt
x x Tight and not loose visual I 5 M Engg bB
Mechanical 9Drive chain
2 x x x Lubricated tight and no damage. visual & physical N I 10 M Engg bB
Mechanical 10Motor mounting
2 x x bolt are tight visual I 4 M Engg bB
Mechanical x x x Not damaged. visual & physical N I 2 M Engg bB
OPS x Not damaged. 2 M Engg bB
Mechanical 12Motor coupling bolt
16 x x Tight visual I 6 M Engg bB
Mechanical 13Drive wheel &sprocket
2 x Not damaged. visual I 2 M Engg bB
Electrical x x Not worn out, air pressure, bolts tight visual I 40 M Engg bB/A/C
OPS x Not worn out visual N 5 D OPS b bB/A/C
Mechanical 15Brake adjustment
2 x x Per indicated adjustment visual I 10 M Engg bA/C
Mechanical 16Trurstor brake mounting
2 x x Tight visual I 4 M Engg bA/C
Electrical x x x Clean and not damaged. visual & physical N I 40 M Engg bB
OPS x Clean and not damaged. visual N 10 D OPS Forman bB
Electrical x x x Clean and not damaged. visual & physical N I 10 M Engg bB
OPS x Clean and not damaged. visual N 10 D OPS Forman bB
Electrical 19hydrulic tank oil level guage
2x
x x Clean and visible and no damged visual & physical N I 10 M Engg bB
Electrical 20Hydraulic Power Pack solenoid coils
12 x x Clean and tightness connections. visual I 30 M Engg bB
Electrical 21Hydraulic Power Pack temperature guage
2 x x Clean and visible and no damged visual I 10 M Engg bB
Electrical 22Motor terminal conection
2x
x Clean and tightness connections. visual I 30 3M Engg bB
Electrical 23 Motor insulation value check 2 x x Check with Megger 50 to 100 mmegaohms visual I 40 M Engg bB
Mechanical 24Cylinder
4 x x Check for leak visual I 5 M Engg bB
Mechanical 25Cylinder pin
8 x x Intact visual I 5 M Engg bB
Mechanical 26Check hydraulic hoses
20 x x Clean and No leak visual I 10 M Engg bB
Mechanical 27Power Pack oil level and leaking check
2 x x Clean and No leakages visual I 10 M Engg bB
Mechanical 28Motor coupling check
2 x x x Check for damaged and tightness. visual & physical N I 4 M Engg bB
Tire guard chain
Wheel Driving
Motors & Gearboxes
Gantry
Eroomside &
Engine Side
Wheel Turning
System
Equipment description : RTG-37 Equipment number : RTG 37
Gantry anticollision limit switch 8
4
24
4Sensors
LImit Switches
Gantry warning device(horn&light)
Tire 8
2
2
14
17
18
11
3
AM Step 3: Equipment standard implementation plan (RTG)
AM Step 3: Equipment check sheet implementation plan (TT)
Number of 120 AM Operators start
implementation in TT , EH , RS
Planned Maintenance Key Activity Indicators (KAI)
Skills Matrix of Engineering Operators
Important Technical Grey Areas 1. Engines 2. Drives 3. PLC 4. Wire Rope
Inspection & Service
Engineering Operators Trainings YTD Since Y-14
Total No. of In-house Trainers 14
Trainings Sessions -94 Participants -1322
PM Improvement Projects Y-13 & Y14
No. Project Project Leader Section Project Type Start Date Status Hard Savings (OMR)
1 RTG Engine Oil Filtration Ahmed Tabook Engineeing A3 PDCA Mar-13 Completed 37,000
2 Boom Wire Rope Spool Modification Akash Morey CM A3 PDCA Oct-13 Completed 3,000
3 QC Spreader Breakdown 2 Akash Morey Planning GB Nov-13 Completed 25000
4 QC Drive Faults Said Al Mujaibi Automation GB Nov-13 Completed 146266
5 Outsourced Asset Optimization Ansar Haider PP GB Nov-13 Completed 70,000
6 Unplanned Wire Ropes Tariq Al Haraizi Planning A3 PDCA Jan-14 Completed 64,400
7 Bromma PLC Recycle Shady Kamal Automation A3 PDCA Jan-14 Completed 3,600
8 Engineering Tools Savings Akash Morey Planning A3 PDCA Jan-14 Completed 42,267
9 Lighting Load Curtailment Ansar Haider PP A3 PDCA Jan-14 Completed 11,642
10 RTG Spreader Refurbishment Saleh Salim CM A3 PDCA Jan-14 Completed 20,637
11 Workshop 4 Shift System Suhail Akaak Engineeing A3 PDCA Feb-14 Completed 82,279
12 In-house CMS & PC Repairs Shady Kamal CM A3 PDCA Mar-14 Completed 11,790
13 Festoon Roller Local Repairs Murugiah Velladuri CM A3 PDCA Apr-14 Completed 8,625
14 Spare Part Management Project Ahmed Tabook Engg GB Jun-14 Analysis
15 QC Gear Oil & Hydraulic Oil interval Change Akash Morey Planning A3 PDCA Aug-14 Control 10000
16 RTG Gear Oil & Hydraulic Oil interval Change Akash Morey Planning A3 PDCA Sep-14 Control 11000
17 Elevator Refurbishments Shady Automation PDCA Sep-14 Control 65,000
18 Weighbridge Refurbishment Ansar Haider PP A3 PDCA Oct-14 Completed 12,280
19 HV Cable Guide Roller Local Repair Murugiah Velladuri CM A3 PDCA Oct-14 Completed 5,000
20 DC Motors refurbishment Abdus Samad Reliability PDCA Dec-14 Completed 60,000
21 HV Slip Ring Enclosure Improvements for zero flashover in 2015 Abdus Samad Reliability PDCA Dec-14 Control 3,080
Improvement Projects Y-15
No. Project Project Leader Section Project Type Start Date Status Hard Savings (OMR)
22 Tire Damage Cost reduction Musallam Habkook Engg PDSA Jan-15 Control 65,000
23 CBM through Ultrasound and IR Abdus Samad Reliability PDCA Jan-15 Measure TBA
24 Electronic Cards repair Abdus Samad Reliability PDCA Feb-15 Analysis 21,148
25 RTG & TT Engine CBM Overhaul-2 Akash Engg PDSA Feb-15 Analysis 40,000
26 Monitoring_RCMS_QC Shady Automation PDCA Feb-15 Measure TBA
27 Carbon Brush Initiative in DC Motors repair Abdus Samad Reliability PDCA Feb-15 Control 4,644
28 Spare Part Recycle –QC Spreader Mohammed Automation PDCA Apr-15 Analysis 10,000
29 Standardization of QC PLC Said Automation PDCA Apr-15 Control TBA
30 Twistlock Lock outside incidents reduction Shady Automation GB Apr-15 Control TBA
31 Hoist Position Standarization Mohammed Automation PDCA Jul-15 Do TBA
32 GE PLC spare parts recycle Shady Automation PDCA Jul-15 check 27,000
33 GE Drive spare parts recycle Shady Automation PDCA Jul-15 Do TBA
34 QC Obselete Drives Alternatives Mohammed Automation PDCA Jul-15 Plan TBA
35 GE QC LCMS shady Automation PDCA Aug-15 Plan TBA
36 Insourcing Cavotec Contract Suhail Akaak Engg PDCA Jun-15 Analysis 115,007
37 Insourcing Facility Contract Suhail Akaak Engg PDCA Jun-15 Analysis 121,757
Total Hard Savings of Improvement Projects = 1,097,422 OMR
Indicator
(PQCDSM)
Sr.
N
o.
U.O.M
Baseli
ne
2013
Targ
et
2014
Targ
et
201
Dec-14 Jan-15 Feb-15 Mar-15 Apr-15 May-15 Jun-15 Jul-15
1 No. Breakdowns due to poor skills / Month No. 485 388 192 125 127 125 114 107 105 88 74
2 No. Accidents to poor skills / Month No. − − 4 3 4 5 2
3 CT Absenteeism Rate / Month % 1.4% 1.1% ### 1.0% 1.1% ### 1.1% 1.3% 1.0% 0.90 0.60
Cost 4 Financiel Impact / net resolt OMR -255.80 ###### 22,064.60 35,769.40 31,708.00 6,517.60 31,499.80
Morale
Productivity
Key Performance Indicators
Education & Training Activity Review, KPI & KAI
Engineering & GCT Standard Operating Procedures (SOP)
TPM preparation phase .
TPM Kickoff .
TPM progress in first phase
Results .
Content
Improvements in TPM Journey:
Indicator (PQCDSM) Sr.No. U.O.M Y-14 Vs Y-13 YTD -15 Vs. Y-14
Productivity
1 QC Breakdowns / 10 K moves No. -24% -25%
2 RTG Breakdowns / 10 K moves No. 14% -12%
3 TT Breakdowns / 10 K moves No. 7% -19%
4 QC MTBF Hours/Month 32% 33%
5 RTG MTBF Hours/Month 1% 21%
6 TT MTBF Hours/Month 1% 34%
7 Availability increase % 1% 1%
Cost
7 Engineering M&R Cost OMR -7% -20%
8 Engineering M&R Cost/Move
OMR/Move 1% -3%
QC Breakdowns
RTG Breakdowns
TT Breakdowns
Improve : Primary Matric Result
3
1 0
2
5 4
2
2
1
7
1
2
7
1
2
4
2
3
1
3
0
1
0
1
0 0 0 0 0 0
1
2
3
4
5
6
7
8
W0
2
W0
3
W0
4
W0
5
W0
6
W0
7
W0
8
W0
9
W1
0
W1
1
W1
2
W1
3
W1
4
W1
5
W1
6
W1
7
W1
8
W1
9
W2
0
W2
1
W2
2
W2
3
W2
4
W2
5
W2
6
W2
7
W2
8
W2
9
W3
0
W3
1
W3
2
W3
3
W3
4
W3
5
W3
6
W3
7
W3
8
W3
9
W4
0
W4
1
W4
2
W4
3
W4
4
W4
5
W4
6
W4
7
W4
8
W4
9
W5
0
W5
1
W5
2
No
. of
un
con
tro
lled
Tw
istl
ock
lock
ou
tsid
e in
cid
en
ts
Primary Metric Graph: uncontrolled Twistlock lock outside incidents
uncontrolled Twistlock lock outside incidents Baseline Objective N
New Average
Breakdowns and Absenteeism (2013 – 2014 & 2015)
Operational Breakdowns for
all POS equipment Absenteeism
In Control
2.1%
1.9%
2.0%
1.6% 1.6%
1.3%
1.0%
1.3%
1.1%
0.9% 0.9% 0.9%
0.94% 0.87%
1.14%
0.95%
1.29%
1.70%
0.90%
1.20% 1.20% 1.1%
1.0% 1.0% 1.10%
1.20% 1.10%
1.30%
1.00% 0.90%
0.60%
0.0%
0.5%
1.0%
1.5%
2.0%
2.5%
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
2013 2014 2015
268
347
554
431
664
367
266
199
108 101 127
72
155 138
165 144
164 198
259 279
238
149
108 125 127 125 114 107 105
88 74
0
100
200
300
400
500
600
700
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
2013 2014 2015
In-House Trainers.
Port of Salalah | PO. Box: 369 | Salalah - 211 |
Sultanate of Oman
email: info@salalahport.com | www.salalahport.com