“TPM – Process Industry” by
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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..
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�
Let’s go thru the case study of Grinding Unit , Kalol
WHY TPM @JKLC, KALOL ??? “To Make Kalol Grinding Unit The Best Grinding Unit Among All Cement Companies”
MILE STONES OF JKLC FOR TPM CERTIFICATION Zone division and cross functional teams prepared June-2013 Team Building Workshop Arranged Sep. 2013
Kicked off TPM with consultant Aprill-2013
Rigorous TPM execution startedOct. 2013
Second Internal Audit November– 2014 First Internal Audit January-2014 Cleared Audit of TPM Level-1 December -2014
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.
PROJECT INITIATION THRU LEAN-TPM Training
8 PILLARS OF TPM
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.
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 OTHERS Maintenance dept----PM only
AUTONOMOUS MAINTENANCE • 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 • 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
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
AUTONOMOUS MAINTENANCE 7-Steps of Autonomous Maintenance • Initial cleaning • Counter measures • Provisional checklist • General inspection and tagging • Autonomous inspection • Standardization • Autonomous management
INITIAL CLEANING
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?
PROVISIONAL CHECKLIST • Display-Who/What/ When/ How? • Fix day of the week, time & team to do the same tagging & untagging
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.
One Point Lesson
BIDCO Elianto Div
Prepared by: ……….. Approved by ………. Prepared on: ……… Administered by …….
Type: Basic Knowledge: V-Belts
Wrong
Vibrating belt indicates that belt is loose
OPL Number:
Correct
No vibration/oscillation of V belt indicates proper fit
AUTONOMOUS MAINTENANCE Finally •
Make a AM Board
•
Put up 4 things on the board:
1. Look for list 2. Tag graph 3. Cleaning Schedule 4. OPL
One Point Lesson
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)
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.
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
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.
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.
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.
8 PILLARS OF TPM
• J:\JKLC\TPM External Audit Level -1\8 pillar doc st
TPM MEASURE: 1 OEE 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 • Performance Factor = (Actual O.P/Total O.P)*100 • Quality Factor= (Good O.P/Actual O.P)*100
TPM MEASURE: 2 MTBF MTBF(Mean time between failure) = Total running time /Number of breakdowns
TPM MEASURE: 3 MTTR MTTR(Mean time to repair) = Total down time /Number of breakdowns
0.6 0.72 0.72
0.8 0.98
0.94
0.93
0.88 0.94
0.85
0.85
1.03 0.95
0.88 0.91
0.82 0.84
0.86
0.94
0.96 0.99
0.9 0.97
0.84 0.91
0.84 0.88
0.87 0.92
0.89 0.94
0.87 0.94
0.85
0.87 0.94
0.91 0.96
0.97 1.01
0.93 0.98
1
1 0.95
0.92 0.87
0.82 0.86
TPM MEASURE 1: OEE
1.2
0.4
0.2
0 41306 41365 41426 41487 41548 41609 41671 41730 41791 41852 41926 41275 41334 41395 41456 41518 41579 41640 41699 41760 41821 41896 41957 OPC
Exponential (OPC)
PPC
TPM MEASURE 2: MTBF Clutch Jam Torsion Shaft
567 gb1 lppb operate CA Fan
567 BE1 Main Drive Fault
Mill i/l oil Pr. Low Water Spray System
Pinion Bearing Mill oil Temp. High 480
480 360 240
240
360
480
120 360
240
240 60 240 120 120 120 120 120 120
120
120 120 120
013 TO JUL-2013
240 240
240
120 120
24 360
240
240
120 240
360
AUG-2013 TO NOV-2013
DEC-2013 TO MAR-2014
240
120
120 360 480
APR-2014 TO JUL-2014
AUG-14 TO NO
TPM MEASURE 3: MTTR 650 550 450 350 250 150
AUG-14 TO NOV-14
APR-2014 TO JUL-2014
DEC-2013 TO MAR-2014
APR-2013 TO JUL-2013
-50
AUG-2013 TO NOV-2013
50
Clutch Jam 567 gb1 lppb operate 567 BE1 Mill i/l oil Pr. Low Pinion Bearing Torsion Shaft CA Fan Main Drive Fault
Trainings
Shop floor Clearing @5
Kaizen New Bag Filter For Dust Control (Developed In-House)
Let Us Make Our Plant A Better Plant Every Moment.
Kaizen Fly Ash Unloading System One Truck Unloading Time - 14- 16 Minutes (Qty -17 Ton) Two Trucks Unloading Time - 18- 21 Minutes (Qty -34 Ton) Three Trucks Unloading Time - 40- 45 Minutes (Qty -51 Ton)
Benefits:
1. Power Saving 2. Effective fleet utilization 3. Effective Plant Area Utilization ( Parking )
Kaizen
TEAM BUILDING WORKSHOP
Glimpse of JKLC Plant STORES Before
After
Glimpse of JKLC Plant Cement Mill Area Before
After
Glimpse of JKLC Plant Scrap Yard Area Before
After
Glimpse of JKLC Plant Visuals at Shop floor and Lab
Rewards for TPM Quiz
Awarded as TPM Certified Organization
TPM Benefits 1. OWNERSHIP & RESPONSIBILITY 2. EFFECTIVE INVENTORY UTILISATION & CONTROL 3. BRINGING STAFF CLOSER TO THE MACHINES & PROCESSES 4. TEAM BUILDING 5. ENHANCE PLANT AESTHETICS 6. INNOVATIONS GALORE 7. OUT OF BOX THINKING
Road Map -Year 2015  Lean Certification for implementing overall lean tools in organization
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