Total Productive Maintenance (TPM) in Process Industry - ADDVALUE - Nilesh ...
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Best Performing Consulting Organization
by
“TPM – Process Industry”
Adding Value In Totality !!
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PROCESS INDUSTRY MEANS??
Those industries where primary processes are either continuous , or occur on a batch of materials that is indistinguishable e.g. Food processing ,cement industry, steel industry etc..
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WHY TPM IN PROCESS INDUSTRY ?
In Process Industry - The whole structure is based on
machineries mainly.- The best way to earn profit is effective
utilization of machineries which can be done by maintaining machines in good condition
“ TPM is the solution of all problems”
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Let’s go thru the case study of
Grinding Unit , Kalol
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WHY TPM @JKLC, KALOL ???
“To Make Kalol Grinding Unit The Best Grinding Unit Among All Cement Companies”
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MILE STONES OF JKLC FOR TPM CERTIFICATION
Second Internal Audit November– 2014
Cleared Audit of TPM Level-1 December -2014
First Internal Audit January-2014
Rigorous TPM execution started- Oct. 2013
Team Building Workshop Arranged Sep. 2013
Zone division and cross functional teams prepared June-2013
Kicked off TPM with consultant Aprill-2013
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WHAT IS TPM??
• To become a world class organization, Organizations must achieve the following:
- World class processes- World class people
- World class machines• TPM is a tool which ensures that organization
attain and sustain world class machines.
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PROJECT INITIATION THRU LEAN-TPM Training
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8 PILLARS OF TPM
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FOCUSED IMPROVEMENT
• The pillar follows a structured set of steps aligned to the Plan, Do, Check, Act (PDCA) cycle, which can be implemented for improvement activities of any size or complexity in any organisation.
• The pillar builds an understanding and analysis of the different loss types affecting an organisation. The pillar operates at a strategic level, identifying the criteria for project selection and TPM deployment that will deliver the business objectives.
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AUTONOMOUS MAINTENANCE
• This pillar is called Jishu Hozen (Autonomous Maintenance) AM itself is a 7 Step process
• What is Autonomous ?? It means driven by self Self maintained INDEPENDENT OF OTHERSMaintenance dept----PM only
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• It is maintenance that is done autonomously ? (by the ‘self’ !!)
• Now who is the ‘self’ ?? It is the operator(s)• A TPM pillar, which aims at ensuring that the
BASIC CONDITION of the M/c / Equipment is maintained by the operators them self.
AUTONOMOUS MAINTENANCE
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• Cleaning - Dirt – poor or improper cleaning
• OILING - No or inadequate oiling / lubrication
• TIGHTENING - Neglecting early signals of vibration, mis-alignment, tightening bolts etc.
• And reduce it and bring it back to its NORMAL life / or basic condition
AUTONOMOUS MAINTENANCE
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JKLC First 10 months only & only COT
• Rigorous cleaning is the only way to reduce break downs
• Visual on machines lead to habitual cleaning to workers
• TPM-Lean focuses on Visuals
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7-Steps of Autonomous Maintenance• Initial cleaning• Counter measures• Provisional checklist• General inspection and tagging• Autonomous inspection• Standardization• Autonomous management
AUTONOMOUS MAINTENANCE
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INITIAL CLEANING
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COUNTER MEASURES
• Improve the condition of the machine so that less time is spent in maintaining it.
• Maintenance time must be targeted nearby 10 minutes /shift. If the maintenance time is high then identify why it takes more time?
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PROVISIONAL CHECKLIST
• Display-Who/What/ When/ How?• Fix day of the week, time & team to do the
same tagging & untagging
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OPL – One Point Lesson
• When you find ABNORMAILITY in M/c – you tag it.
• But.. when you find a ABNORMILITY in operators – you use a OPL.
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One Point Lesson
Prepared by: ……….. Approved by ……….Prepared on: ……… Administered by …….Type: Basic Knowledge: V-Belts
Wrong Correct
BIDCOElianto Div
OPL Number:
Vibrating belt indicates that belt is loose
No vibration/oscillation of V belt indicates proper fit
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Finally• Make a AM Board• Put up 4 things on the board:1. Look for list2. Tag graph3. Cleaning Schedule4. OPL
AUTONOMOUS MAINTENANCE
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One Point Lesson
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PLANNED MAINTENANCE
• Generally lead by maintenance team• The initial phase prioritises equipment and
involves evaluating current maintenance performance and costs to set the focus for the pillar activity.
• It can be done based on cost effectiveness suits the system (CBM/TBM)
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TRAINING AND EDUCATION
• The knowledge and skills required for carrying out each job are defined, in terms of both complexity of knowledge needed and the number of capable people required to support the business needs.
• A current state analysis assesses the current levels against the established requirements and a training plan is developed to close any gaps.
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EARLY MANAGEMENT
• Early Equipment Management focuses on reduction of defect free process so equipment down time is minimal
• Early Product Management aims to shorten development lead times, with teams working on simultaneous activities so that vertical start up can be achieved with zero quality loss
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QUALITY MAINTENANCE
• Quality Maintenance is implemented in two phases.• The first phase aims to eliminate quality issues by
analysing the defects, so that optimum conditions can be defined that prevent defects occurring.
• Then, the current state is investigated and improvements are implemented.
• The second phase ensures that quality is sustained, by standardising the parameters and methods to achieve a zero defect system.
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OFFICE TPM
• Office TPM team implement office versions of Focussed Improvement and the Training and Education pillars to establish sustainable, performing processes.
• To make office work smooth, office TPM is focused using 5S,LBM etc.
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SAFETY, HEALTH AND ENVIRONMENT
• SHE pillar activities aim to reactively eliminate the root causes of incidents that have occurred, to prevent Reoccurrence, and proactively reduce the risk of future potential incidents by targeting near misses and potential hazards.
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8 PILLARS OF TPM
• J:\JKLC\TPM External Audit Level -1\8 pillar doc status.xls
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OEE= A factor * P factor * Q factor• Availability Factor = (Run time/ Net operating time)*100,• Calendar time = 30*24* 60 = 43200 min• Net operating time = Calendar time- (planned
shutdown+ no schedule production + planned maintenance)
• Run time = Schedule O.T. - Down time losses
TPM MEASURE: 1 OEE
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• Performance Factor = (Actual O.P/Total O.P)*100• Quality Factor= (Good O.P/Actual O.P)*100
TPM MEASURE: 1 OEE
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MTBF(Mean time between failure)= Total running time /Number of breakdowns
TPM MEASURE: 2 MTBF
TPM MEASURE: 3 MTTRMTTR(Mean time to repair)= Total down time /Number of breakdowns
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Jan/13
Feb/13
Mar/13
Apr/13
May/13
Jun/13
Jul/13
Aug/13
Sep/13
Oct/13
Nov/13
Dec/13
Jan/14
Feb/14
Mar/14
Apr/14
May/14
Jun/14
Jul/14
Aug/14
Sep/14
Oct/14
Nov/14
OPC
0.82 0.72 0.92 0.95 0.93 0.97 0.91 0.87 0.85 0.87 0.89 0.87 0.84 0.84 0.90 0.96 0.94 0.86 0.82 0.88 0.85 0.85 0.88
PPC
0.86 0.72 0.87 1.00 0.98 1.01 0.96 0.94 0.98 0.94 0.94 0.92 0.88 0.91 0.97 0.99 1.03 0.95 0.84 0.91 0.93 0.94 0.94
0.10
0.30
0.50
0.70
0.90
1.10
0.82
0.72
0.92 0.
95
0.93 0.
97
0.91
0.87
0.85 0.87 0.89
0.87
0.84
0.84 0.
90
0.96
0.94
0.86
0.82 0.
88
0.85
0.85 0.
88
0.86
0.72
0.87
1.00
0.98 1.
01
0.96
0.94 0.
98
0.94
0.94
0.92
0.88 0.
91 0.97 0.99 1.
03
0.95
0.84
0.91 0.
93 0.94
0.94
OPCExponential (OPC)PPCExponential (PPC)
TPM MEASURE 1: OEE
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TPM MEASURE 2: MTBF
APR-2013 TO JUL-2013 AUG-2013 TO NOV-2013 DEC-2013 TO MAR-2014 APR-2014 TO JUL-2014 AUG-14 TO NOV-14
120240
360480
600
120120
240
36060
120
240
360 120 240
120
24024 120 120
120
240 120
240 360
120
240120
240360
120
240 360
480
600
120
60120
240120
120
240
360
480
600
120
240
360
48060
Mill oil Temp. High Water Spray System Main Drive Fault CA Fan Torsion ShaftPinion Bearing Mill i/l oil Pr. Low 567 BE1 567 gb1 lppb operate Clutch Jam
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TPM MEASURE 3: MTTRAP
R-20
13 T
O JU
L-20
13
AUG
-201
3 TO
NO
V-20
13
DEC
-201
3 TO
MAR
-201
4
APR-
2014
TO
JUL-
2014
AUG
-14
TO N
OV-
14
-50
50
150
250
350
450
550
650
Clutch Jam567 gb1 lppb operate567 BE1 Mill i/l oil Pr. LowPinion Bear-ingTorsion ShaftCA FanMain Drive FaultWater Spray SystemMill oil Temp. High
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Trainings
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Shop floor Clearing @5
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Let Us Make Our Plant A Better Plant Every Moment.
New Bag Filter For Dust Control (Developed In-House)
Kaizen
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One Truck Unloading Time - 14- 16 Minutes (Qty -17 Ton)
Benefits: 1. Power Saving2. Effective fleet utilization 3. Effective Plant Area Utilization ( Parking )
Two Trucks Unloading Time - 18- 21 Minutes (Qty -34 Ton)Three Trucks Unloading Time - 40- 45 Minutes (Qty -51 Ton)
Fly Ash Unloading SystemKaizen
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Kaizen
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TEAM BUILDING WORKSHOP
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Glimpse of JKLC Plant
STORES Before After
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Before After
Cement Mill Area
Glimpse of JKLC Plant
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Before AfterScrap Yard Area
Glimpse of JKLC Plant
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Visuals at Shop floor and Lab
Glimpse of JKLC Plant
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Rewards for TPM Quiz
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Awarded as TPM Certified Organization
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TPM Benefits
1. OWNERSHIP & RESPONSIBILITY2. EFFECTIVE INVENTORY UTILISATION & CONTROL3. BRINGING STAFF CLOSER TO THE MACHINES &
PROCESSES4. TEAM BUILDING5. ENHANCE PLANT AESTHETICS6. INNOVATIONS GALORE7. OUT OF BOX THINKING
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Road Map -Year 2015
Lean Certification for implementing overall lean tools in organization
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ADDVALUE Services
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Thank You