TPM in Industrial Canteen - OpEx Solutions · TPM in Industrial Canteen 1 ... JH –Jishu Hozen KK...
Transcript of TPM in Industrial Canteen - OpEx Solutions · TPM in Industrial Canteen 1 ... JH –Jishu Hozen KK...
A Journey of Change initiated at
Guwahati Refinery
TPM in Industrial Canteen
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•Fortune 500 company
•Ranked 98th /only Indian company in the first
100 of fortune 500 .
•Largest Refiner of the country
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Care
Passion
Innovation
Trust
CORE VALUES
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First Public Sector Refinery in India
Dedicated to the nation on 1st Jan, 1962
A 49 years old Refinery
Tucked away in the north east corner
GUWAHATI REFINERY ……….INDIANOIL
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OFFICE TPM
IN
HR / CANTEEN5
Drives
The entire factory and work force
Holistic productivity improvement
system
TOTAL PRODUCTIVE MAINTENANCE( TPM )
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TPM
Conference Hall
HR
Implementation
Knowledge and Implementation
Cycle
HR Facilitator
Guest House Canteen
HR Hall
CONCEPTUALIZATION AND IMPLEMENTATION OF OTPM
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Aims at improving Office
efficiency, productivity
and reduce Time losses in
Office processes and
procedures
OFFICE TPM
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OTPM follows a Five Pillar approach from conceptualization to implementation :
JH – Jishu Hozen
KK – Kobetsu Kaizen
E&T- Education &Training
PM - Planned Maintenance
SHE – Safety, Health and Environment
THE FIVE PILLAR APPROACH
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THE OFFICE OF 2007
Our Workplaces Looked Like This 10
Segregation of useful / wasteful records and documentation
Thoroughly cleaned tables, drawers and cabinets
Elimination of unnecessary documents
Indexation of all documents / files
Pre-fixed locations on tables / drawers / storage units
Creating a master record for all files & documents
Easy locating devices for the documents
APPROACH ADOPTED THROUGH 5 ‘S’
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SORTING…WEEDING
….. AND CLEARING
Initial 8 / 10 months
10 truckloads sorted out
EMPLOYEE ACCEPTANCE………..EMPLOYEE INVOLVEMENT
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Conceptualized By Employees
NEW OFFICE INFRASTRUCTURE - NEW AMBIENCE
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BEFORE AFTER
File cabinet in office hall Right thing at right place
FILING SYSTEMS WITH VISUAL MANAGEMENT
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FILE SYSTEM WITH COLOUR CODING AND INDEX
Visual Management
More than 5000 files in HR Dept
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FILE SEGREGATION AND FILE INDEX
File Index
Ownership
Indicator
Visual Management16
MASTER COLOR CODING AND LOCATION INDICATOR
Visual Management17
HR / SDU / 01 / HBA / 003 / 024
Page Code
Name of the Department
SDU Sl No.
Subject Area
File Number
Sheet Number
SDU/ Compactor
Document Retrieval Time Achieved : 30 – 35 seconds
INNOVATION : STANDARDIZED SHEET CODING
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M
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E
S
YEAR
Better
PHASE WISE REDUCTION IN FILE RETRIEVAL TIME
Document retrieval < 35 seconds
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DESIGNATED PLACE FOR EVERYTHING
Office Table Stationary DrawerOwnership Labels20
Maintained On Rotation by HR Staff
DAILY MAINTENANCE CHECKLIST
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Employee seat Locations withEmployee Photographs
Workstation Wise EmployeeSeating and Job Areas
SEATING LAYOUT CHARTS
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ELIMINATION OF NVA
25 processes, 30% Saving achieved in Response
Time 23
List Index For Files In SDURack wise – Number wise
Office Equipment Ownership
HR HALL DISPLAY
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Response time Indicator
Efficiency Indicator
• Records incoming/outgoing HR applications
• Average Response time calculated and indicated every week
• HR efficiency evaluated and available on display
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TPM AT REFINERY
OVERVIEW OF TPM AT GUWAHATI REFINERY 26
PH - OMS
TPM AT GR REFINERY
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Why Canteen ???
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WHY CANTEEN ?
Scope for Improvement
Delightful
Services
2007
Parameters of Services
Establishment, Loans & Advances, Canteen Services, Guest House, Administration, Event Management, Furniture and Office MaintenancePost Retirement Services
Employee Satisfaction Index On HR Services
41 %
Others 40%
Canteen Services
60 %
Dissatisfaction Index on
Canteen services
59 %
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Systematically reduce Response Time
√ Develop /Turnaround Canteen into a Model Industrial Canteen
Strive for Employee Delight in all HR services
Identify and Remove Non Value Added Services in all areas
Computerize HR work processes for reducing processing time
HR Goals - 2008
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No tracking/planning
For Grocery
ProcurementIndividual Work
Style-No system
approach
Poor ambience in
offices / storeroom
Average Food QualityPoor Hygiene
And cleanliness
Improper Storage of
Materials/Food Stuff
Canteen Of
2007Improper waste
Disposal
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OUR CANTEEN HALL OF 2007
Dull, Ordinary, and non vibrant32
THE STORY BEFORE TPM…
No system for storing Grocery!
No means of tracking the Grocery levels!
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No means of food waste disposal!
THE STORY BEFORE TPM…
Customer Dissatisfaction 34
ENHANCE CUSTOMER
SATISFACTION
Organic Waste
Disposal
Automation for
Customer Delight
Systematic Documentation of Office Records
Introduce Grocery
Tracking Systems
Ownership Systems
For
Maintenance/Upkeep
OBJECTIVES
IdentifiedImprove
Ambience and Hygiene
Improve Food Quality
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Change…….Change...Change...Ideas
THE FOCUS OF ALL NEW EFFORTS
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A NEW VISION
Ordinary
Workmen
Canteen
Unique/Ambient
Industrial
Canteen
Of High
standards
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Autonomous Maintenance
Focused Improvement
Planned Maintenance
Quality Maintenance
Early Management
Safety, Health & Environment
Education & Training
OTPM
8 PILLAR APPROACH INITIATED
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AUTONOMOUS MAINTENANCE
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Kitchen Equipments
STEAM
Boiler
ROTI MAKER
OWC
Burners
POTATO
PEELER
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AUTONOMOUS MAINTENANCE
SOP for OWC & Checklist for maintaining all the equipments in Kitchen.
Maintenance of Automatic Rotimakerthrough Checklist
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FOCUSED IMPROVEMENT
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FOCUSED IMPROVEMENT FOR FOOD WASTE
DISPOSAL
OWC
Surrounding areas getting littered by canteen waste, foul smell, no daily
clearance by Civil Contractor, dependence on outside agencies
OPTIONS :
• Tie up with PWD
•Have own system
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RECYCLING ORGANIC FOOD WASTE
Collection of Organic Food waste from Canteen daily
Removal of steel, glass and plastic particles/items from the waste
Shredding the bigger hard items like bones, lemon pieces etc into the shredder
Grinding the remaining waste into the OWC along with saw dust and chemicals
Culturing the processed waste into manure through the pruning system in 10 days.
Using the manure in cultivation of plants in and around refinery.
The manure prepared from OWC is used in the refinery and township garden 45
RECYCLING ORGANIC FOOD WASTE
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KAIZEN FOR RECYCLING ORGANIC FOOD WASTE
FOCUSED IMPROVEMENT
• Old closed vessel
Storage for grocery
• No means to clean inside
• Materials get drawn
from top regularly
• No means to track
consumption levels
Earlier Storage Systems
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Focussed Improvement
Phase 1 Phase 2
Transition
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FOCUSED IMPROVEMENT
Pondering on challenging assignment posed by Japanese auditors
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Idea of new vessel with transparent strip / Bottom valve
Why Not POKA YOKE ?
(mistake Proofing)
FOCUSED IMPROVEMENT
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Transparent Strip introduced for
Grain level visibility without
opening lid cover
Bottom Opener for Drawing out
Material – FIFO Concept
DESIGNED BY TPM CIRCLE EMPLOYEES
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FOCUSED IMPROVEMENT
FIFO System For Grocery
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PLANNED MAINTENANCE
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PLANNED MAINTENANCE
Daily Check listing for Maintaining, Grocery Room, Kitchen, Grocery Level, Main Hall
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MAINTENANCE OF AUTOMATIC ROTI MAKER (ARM)
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MAINTENANCE OF ORGANIC WASTE CONVERTER (OWC)
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REGULAR MAINTENANCE THROUGH CHECKLISTING
Regular Monitoring of Checklist by Senior Officer. 57
QUALITY MAINTENANCE
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QM – Display of Brands Of Raw Materials Used
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QUALITY MAINTENANCE
Weekly inspection by Nutritionists
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QUALITY MAINTENANCE
Surprise Inspection by Canteen Committee
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SERVICE QUALITY MAINTENANCE
Introduction of a Suggestion Book
Collect feedback on Food, Ambience and Hygiene Conditions
daily
Review the Suggestion at the end of each day
Take action on immediate problems
Take up critical suggestion in weekly meeting
Implement improvement in the service
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EARLY MANAGEMENT
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EARLY MANAGEMENT
Learning From Experience
To Learn from Guwahati experiences , HR Heads Meet of all IOCL Refineries held in September’10
GR Canteen benchmarked for Display, Storage and SHE systems
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EARLY MANAGEMENT
HR Heads of Other Refineries having on spot experience
Of change
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SAFETY, HEALTH & ENVIRONMENT
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SAFETY
Safety gloves, shoes, mask and apronDisinfecting and Pest Control
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SAFETY
Cooks working in Kitchen and a boy serving food to guests68
INPUTS ON HEALTH/HYGIENE
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HEALTH
BMI Measurement in Canteen Hall 70
Pictorial Charts on Health/Nutrition in Canteen Hall 7171
ELECTRONIC SCROLLER ON HEALTH/
NUTRITION TIPS
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SHE : CARE FOR ENVIRONMENT
Treats Organic Waste (Food Left
Over, Raw Vegetables etc.) 60-70
KG of waste per day into Manure
Eco friendly treatment
Manure is used in Public Flower
Parks and Nurseries in and around
Refinery campus.
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EDUCATION & TRAINING
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EDUCATION AND TRAINING
TYPES OF TRAINING
In house Training
Sponsored Training outside Refinery
•TRAINING PROGRAMMES
Soft Skills training by Hotel Management faculty twice in a year with practical classes
Safety training by F&S dept every 6 months.
Training by Nutritionists on preparing healthy balanced food.
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SOFT SKILLS INPUTS BY HOSPITALITY EXPERTS
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ONE POINT LESSON
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OFFICE TPM
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OTPM - RE-ORDER LEVEL IN GROCERY MANAGEMENT
Material Re-Order Level is defined and indicated in each storage vessel/rack for proper tracking
Green Colour
Yellow Colour
Red Colour
SU
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OC
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RE
-OR
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VE
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CR
ITIC
AL
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OC
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MATERIAL RE-ORDER LEVEL CHART
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Office and Storage
A place for everything and everything in its place
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Visuals
Planning & Scheduling Standardization
Color Code Identity Chart
For Using → Switches in
Canteen Hall
Color Codes For Lights , fans and Fittings
in Hall
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Checklist for maintaining Plant Canteen
CHECKLISTING & OWNERSHIP
Grocery Room Ownership indicator
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OTPM : RE-ORDER LEVEL IN GROCERY MANAGEMENT
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OTPM : RE-ORDER LEVEL IN GROCERY MANAGEMENT
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OTPM : IMPROVED GROCERY MANAGEMENT
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ONLINE MEAL BOOKING SYSTEM
•Better Planning•Less Food Wastage
•Cost Monitoring
Intranet Card Reader
Electronic Kiosk
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Winning TPM awards by Canteen Team
A Routine Affair
Participation In TPM Competitions
The Winning Team
We Own And Proudly Maintain
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With a
Difference
An Industrial Canteen
WHAT DID WE ACHIEVE ?
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CLEAN AND PLEASANT AMBIENCE
Turnaround ………Industrial Canteen 2011 91
A PLACE FOR ENJOYABLE MEALS FOR ALL
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A CURIOUS PLACE FOR VISIT BY CHAIRMAN/VIPS/DIRECTORS
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REGULAR STREAM OF VIPS
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REGULAR STREAM OF VIPS
JIPM Team Visit at Canteen in Jan 2010
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VIP VISITS
Our proud Team with JIPM Team including Prof Yoshio Tanaka San, Mr KinjiroNakano
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TURAROUND ON CANTEEN SERVICES
30%
70%
2007
Delighful Services
Scope for Improvement
75%
25%
2011
Delightful Services
Scope for Improvement
Satisfaction Index
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Providing Hygienic, Quality Food in Ambient Environment
Consistently Strive and Innovate For
MISSION OF CANTEEN STAFF
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Quality Of Services
assessed every Six
Months Areas For
Improvement
Displayed in Chart in
Hall
PERIODIC CUSTOMER FEEDBACK
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They came, saw and Wrote
“Impressed by the cleanliness and orderliness of Canteen. Other organizations in the city must take lessons from them.”
- N. I. Laskar, Executive Editor, Eastern Chronicle
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They Continue to write…
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Proud To Compare
Refinery Industrial Canteen A Mc Donald’s Outlet
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Sustenance
And
More New Interventions
WAY FORWARD
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WAY FORWARD
Strive for Consistent ImprovementWin The TPM Sustenance award - 2012
Team Canteen
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