TPM - Supreme
Transcript of TPM - Supreme
Dr. T Nambirajan, BE, MBA, PhDHead of the DepartmentDepartment of Management StudiesSchool of ManagementPondicherry University
MY SINCERE THANKS TO…
Mr. Sushil PadhyAssistant General managerIndustrial Products DivisionSupreme Industries Ltd.,Unit – 11, Pondicherry
EFFECTIVENESS OF TPM
@IPD, SUPREME INDUSTRIES LTD.,
PONDICHERRYE.P. JOHN
Reg. No. 11397044, DMS, SOM
Phase 1 - IntroductionPlasticsSupreme Industries
Ltd.TPM
Phase 2 - Supreme TPMPillars of TPM
Phase 3 - Supreme TPM PillarsPhase 4 - Problems Indentified with
Probable solutionPhase 5 - TPM Effectiveness
Glimpses of TPM practice
Conclusion
PLASTICS
Crude Oil(Naphtha)
Olefins
Ethylene Propylene
Butadiene
Aromatics
BenzeneTolueneXylene
PLASTICS…
PLASTICS PROPERTIES…
Easy availability. Low cost in case of mass production. Low cost as compared to cost of metal. Long product life. Resistance to corrosion. Water proofing capability. Better surface finish.
Process Operation
Temperature: barrel zones, tool, die zonePressures: injection max, holdTimes: injection, hold, tool openingShot size: screw travel
Flash
Melt
Thermaldegradation
Short-shot
Temp.
Pressure
Processing window
DEFECTS IN INJECTION MOLDING PROCESS
Pour Short Flashing Sink Marks and Voids Weld Lines Shrinkage
PLASTICS AND ENVIRONMENTALISSUESToxicity
Due to their insolubility in water and inertness pure plastic generally have low toxicity in their finished state.
Plastics pass through the digestive system with no ill effects.
Non-degradability Plastics are very durable and degrade very slowly, the molecular bonds that make plastic so durable make it very much resistant to natural process of degradation.
INJECTION MOULDING MACHINES
COMPANY PROFILE
COMPANY PROFILE
Founded in 1942, Supreme is an acknowledged leader of India's plastics industry. Handling volumes of over 190,000 MT annually. 19 advanced plants are powered by technology from world leaders.Complement extensive facilities for R & D and new product development. Exports remain a focal area of operations.Annual Turnover – Rs. 3,900 Crores in 2010.
INDUSTRIAL PRODUCTS DIVISION
PLASTIC PIPING SYSTEMS
MAATERIAL HANDLING PRODUCTS DIVISION
MOULDED FURNITURE
PROTECTIVE PACKAGING DIVISION
PLASTIC FILMS DIVISION
SUPREME PETROCHEMOCALS LTD.
SUPREME EXPANDS AND GROWS…
TOTALPRODUCTIVE
MAINTENANCE(TPM)
TPM - History
TPM is an innovative Japanese concept. The origin of TPM - when preventive maintenance was introduced in 1951. The concept was taken from USA. Nippon Denso was the first company to introduce plant wide preventive maintenance in 1960.
Total Productive Maintenance
TPM means to achieve high level of
productivity, through total participation of all
people inside the organisation and then developing self
managing abilities in people and practices.
Productivity, in JIPM-TPM means increasing production and reducing
cost simultaneously.
TPM OBJECTIVESAvoiding wastage in a quickly changing economic environment.Producing goods without reducing product quality.Reduce cost.Produce a low batch quantity at the earliest possible time.Goods send to the customers must be non defective.
TPM TARGETSP (Product)Obtain Minimum 80% OPE.Obtain Minimum 90% OEE Run the machines even during lunch. Q (Quality) Operate in a manner, that there are no customer complaints.C (Cost)Reduce the manufacturing cost by 30%.
TPM TARGETSD (Delivery)Achieve 100% success in delivering the goods S (Safety)Maintain a accident free environment.M (Morale)Increase the suggestions by 3 times. Develop Multi-skilled and flexible workers.
STEPS FOR TPM STEP A - PREPARATORY STAGE
STEP 1 - Announcement by Management to all about TPM introduction in the organization
STEP 2 - Initial education and propaganda for TPM
STEP 3 - Setting up TPM and departmental committees
STEP 4 - Establishing the TPM working system and target
STEP 5 - A master plan for institutionalizing
BENEFITS OF TPMA Safer WorkplaceAssociate EmpowermentAn Easier WorkloadIncreased ProductionFewer DefectsFewer BreakdownsFewer Short Stoppages (Chokotei)Decreased CostsDecreased Waste (Muda)
STEP BINTRODUCTION STAGE
STAGE C IMPLEMENTATION
STAGE D INSTITUTIONALISING STAGE
STEPS FOR TPM
FOCUSED IMPROVEMENT
Focused improvement includes all activities that maximise the
overall effectiveness of equipment, processes and plants
through uncompromising elimination of losses and
improvement of performance. Select a topic
Form a project teamRegister the topic
Implement the improvementEvaluate the results
AUTONOMOUS MAINTENANCE
Is geared towards developing operators to be able to take care of small maintenance
tasks.
Step – 0 – Know your equipmentStep – 1 – Initial cleaningStep – 2 – Corrections of abnormalityStep – 3 – Establish cleaning, inspection standardsStep – 4 – Perform general inspectionStep – 5 – Perform process general inspection
PREVENTIVE MAINTENANCE
It is aimed to have trouble free machines and equipments producing defect free products for total customer satisfaction.
Preventive MaintenanceBreakdown MaintenanceCorrective MaintenanceMaintenance Prevention
QUALITY MAINTENANCEPrepare QA matrixPrepare production input condition analysis tablePrepare problem chartEvaluate seriousness of problemsUse P-M analysis to track down causes of problemsAssess impact of proposed countermeasuresImplement improvementsReview production – input conditionsConsolidate and confirm check pointsPrepare a quality component control table and assure quality through strict condition control
EDUCATION AND TRAININGEvaluate the current training program and set policy and priority strategiesDesign a program for improving operating and maintenance skillsImplement operating and maintenance skill trainingDesign and develop a skill-development systemFoster an environment that encourages self-developmentEvaluate the activities and plan for the future
TRAINING
NO TRAINING
EFFECTIVE TRAINING
ORGANISATION WINS THE COMPETITION
COMPETITION WINS THE ORGANISATION
+ VE GROWTH
- VE GROWTH
BUSINESS GROWTH…
NORMALBUSINESS
DEVELOPMENT MANAGEMENTClarify the system’s missionFormulate several alternative proposals capable of fulfilling the missionIdentify criteria for evaluating the system and techniques for quantifying theseEvaluate the proposalsDocument the analytical results and processes
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Target line
conventional picture
conventional picture
Overall equipment efficiency
Start-up period
Full-scale operation
immediately after start-up
Full-scale operation
immediately after start-up
N
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uipm
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No. of minor defects
0 0
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Overall equipment efficiency
Start-up period
Target line
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Target line
conventional picture
conventional picture
Overall equipment efficiency
Start-up period
Full-scale operation
immediately after start-up
Full-scale operation
immediately after start-up
N
o. o
f min
or d
efec
tsO
vera
ll eq
uipm
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(%)
No. of minor defects
0 0
N
o. o
f min
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efec
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ll eq
uipm
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(%)
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Overall equipment efficiency
Start-up period
Target line
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Target line
conventional picture
conventional picture
Overall equipment efficiency
Start-up period
Full-scale operation
immediately after start-up
Full-scale operation
immediately after start-up
N
o. o
f min
or d
efec
tsO
vera
ll eq
uipm
ent e
ffici
ency
(%)
No. of minor defects
0 0
N
o. o
f min
or d
efec
tsO
vera
ll eq
uipm
ent e
ffici
ency
(%)
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Overall equipment efficiency
Start-up period
Target line
Development Management and Start-up Period
SAFETY, HEALTH AND ENVIRONMENT
Establish basic safety requirements through,Step – 1 Detect and correct any problems that might affect safety or the environment.Step – 2 Improve safety and environment by eliminating sources of leaks, spills and dust.Step – 3 Establish individual safety routines.
OFFICE TPM
The five core activities for 0ffice TPMIncrease work efficiency through focused improvementBuild a system of administrative autonomous maintenanceImprove administrative capacity through education and trainingCreate an efficient staffing systemDevelop a work evaluation system
SUPREME TPM
TRANSITION CURVE
Denial
Kick-offConsultant IN
Resistance
ResistanceConsultant OUT
Exploration
Commitment
Aug 2007 Jan 2011
SUPREME TPMVision - To grow business with dignity and respect
Mission - To retain a world-class manufacturer of competitive plastic
products.
Core values IntegrityCustomer loyaltyContinuous improvement
InnovationUncompromising qualityEmpowerment to individuals
SUPREME TPM POLICYTPM is a philosophy, which brings results when practised. It achieves the optimum use of resources and obtains best results. Committed to achieve excellence in performance
by achievingZero breakdowns
Zero accidentsZero defects
with the practice of TPM as a way of life by all employees, throughout the
organisation.
Total Performance Managementthrough
Total Productive Maintenancethrough
Total Perfect Manufacturingby
Total employee involvement
TPM EQUALS
5S
TPM starts with 5S. Problems cannot be clearly seen when the work place is unorganized. Cleaning and organizing the workplace helps the team to uncover problems. Making problems visible is the first step of improvement.
5S
Japanese
Term
English
Translation
Equivalent 'S'
term
Seiri Organisation Sort
Seiton Tidiness Systematise
Seiso Cleaning Sweep
Seiketsu Standardisation Standardise
Shitsuke Discipline Self - Discipline
THE 7 QC TOOLSPareto Diagram Cause & Effect Diagram Histogram Control Charts Scatter Diagrams Graphs Check Sheets
TPM EFFECTIVENESS
TPM EFFECTIVENESSManagement IndicatorsPlant Effectiveness IndicatorsQuality IndicatorsEnergy-Saving IndicatorsMaintenance IndicatorsTraining and Morale IndicatorsSafety and Environment
MANAGEMENT INDICATORSOperating profitRatio of operating profit to gross capitalValue-added productivityLabour productivityCost reductionHeadcount reductionReduction in product stock valueReduction in work-in-process valueEquipment investment efficiencyPlant/Labour ratio
PLANT EFFECTIVENESS INDICATORS
Overall plant effectivenessOverall effectiveness of important equipmentAvailabilityPerformance rateStandard production rateAverage actual production rateQuality rateNumber of equipment (plant) failuresNumber of process failures
QUALITY INDICATORSProcess defect rateCost of process defectsNumber of defects passed onNumber of warranty claimsOverall yield
ENERGY-SAVING INDICATORS
Electricity consumptionSteam consumptionFuel consumptionWater consumptionLubricant/Fluid consumptionAuxiliary materials consumption
MAINTENANCE INDICATORS
Reliability and maintainability indicatorsMaintenance efficiency indicatorsMaintenance cost indicatorsOther maintenance indicators
TRAINING AND MORALEINDICATORS
Number of meetingsNumber of FI topics registeredCost savings due to FINumber of suggestionsNumber of outside presentationsNumber of one-point lesson sheetsNumber of PM traineesNumber of official qualifications acquired
FURTHER SCOPE OF STUDY
HR ASPECTS OF INDUSTRIAL CERTIFICATIONSHR ASPECTS OF TPMMARKETING ASPECTS OF CERTIFIED ORGANISATIONS ETC,
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