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