MY SINCERE THANKS TO… Dr. T Nambirajan, BE, MBA, PhD Head of the Department Department of Management Studies School of Management Pondicherry University Mr. Sushil Padhy Assistant General manager Industrial Products Division Supreme Industries Ltd., Unit – 11, Pondicherry
Pour Short Flashing Sink Marks and Voids Weld Lines Shrinkage
ToxicityDue to their insolubility in water and inertness pureplastic generally have low toxicity in their finishedstate.Plastics pass through the digestive system with no illeffects.Non-degradabilityPlastics are very durable and degrade very slowly, themolecular bonds that make plastic so durable make itvery much resistant to natural process of degradation.
Founded in 1942, Supreme is anacknowledged leader of Indias plasticsindustry. Handling volumes of over 190,000 MTannually. 19 advanced plants are powered bytechnology from world leaders. Complement extensive facilities for R & D andnew product development. Exports remain a focal area of operations.
TPM is an innovative Japaneseconcept. The origin of TPM - when preventivemaintenance was introduced in 1951. The concept was taken from USA. Nippon Denso was the first companyto introduce plant wide preventivemaintenance in 1960.
TPM means to achieve high level of productivity, through total participation of all people inside the organisation andthen developing self managing abilities in people and practices. Productivity, in JIPM-TPM means increasing production and reducing cost simultaneously.
Avoiding wastage in a quicklychanging economic environment. Producing goods without reducingproduct quality. Reduce cost. Produce a low batch quantity at theearliest possible time. Goods send to the customers mustbe non defective.
P (Product)Obtain Minimum 80% OPE.Obtain Minimum 90% OEERun the machines even during lunch. Q (Quality)Operate in a manner, that there are nocustomer complaints. C (Cost)Reduce the manufacturing cost by 30%.
D (Delivery)Achieve 100% success in delivering thegoods S (Safety)Maintain a accident free environment. M (Morale)Increase the suggestions by 3 times.Develop Multi-skilled and flexible workers.
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
STEP B INTRODUCTION STAGE STAGE C IMPLEMENTATION STAGE DINSTITUTIONALISING STAGE
Focused improvement includes all activities that maximise the overalleffectiveness of equipment, processes and plants through uncompromisingelimination of losses and improvement of performance. Select a topic Form a project team Register the topic Implement the improvement
Is geared towards developing operators to beable to take care of small maintenance tasks.Step – 0 – Know your equipmentStep – 1 – Initial cleaningStep – 2 – Corrections of abnormalityStep – 3 – Establish cleaning, inspectionstandardsStep – 4 – Perform general inspectionStep – 5 – Perform process general inspection
It is aimed to have trouble freemachines and equipments producingdefect free products for total customersatisfaction. Preventive Maintenance Breakdown Maintenance Corrective Maintenance Maintenance Prevention
Prepare 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 assurequality through strict condition control
Evaluate the current training program and setpolicy and priority strategies Design a program for improving operating andmaintenance skills Implement operating and maintenance skilltraining Design and develop a skill-developmentsystem Foster an environment that encourages self-development Evaluate the activities and plan for the future
BUSINESS GROWTH… EFFECTIVE TRAINING + VE GROWT H ORGANISATION WINS THE COMPETITION NORMALTRAINING BUSINESS COMPETITION WINS THE ORGANISATION - VE GROWT H NO TRAINING
Clarify the system’s mission Formulate several alternative proposalscapable of fulfilling the mission Identify criteria for evaluating the systemand techniques for quantifying these Evaluate the proposals Document the analytical results andprocesses
Development Management and Start-up Period Overall equipment efficiency Start-up period Overall equipment efficiency (%) Overall equipment efficiency (%) — — — Start-up period — — — — — — Full-scale — — Target line Overall Full-scale — operation Target line — equipment operation — efficiency immediately — immediately — No. of minor defects No. of minor defects after start-up — conventional after start-up — conventional — picture — picture — — — 0 0 — — — — — I I In De Ins In M M Ma ns ns D D De itia st ta ta — — co tal al nu nu nu si si sig om om all all lll-p la ph ph mm ing — D — lat ha f c f c fac ec tio n n n as as ion ion ion se — om n — iss iss iss t t tur e e M Pr Pr Pr No. of an m ion ing ing — — on on od od od uf is minor defects si ing ing ing uc uc uc — D ac on — t t ti tu Ini oduc es in on on on nit duc rin g Pr ig tia fo fo flo n g al- tion o l-p i n w w w ha flo se low se w
Establish basic safety requirements through, Step – 1 Detect and correct anyproblems that might affect safety or theenvironment. Step – 2 Improve safety andenvironment by eliminating sources of leaks,spills and dust. Step – 3 Establish individual safetyroutines.
The five core activities for 0ffice TPM Increase work efficiency through focusedimprovement Build a system of administrativeautonomous maintenance Improve administrative capacity througheducation and training Create an efficient staffing system Develop a work evaluation system
Commitment DenialKick-off ResistanceConsultant IN Aug 2007 Jan 2011 Consultant OU Resistance Exploration
Vision - To grow business with dignity andrespect Mission - To retain a world-classmanufacturer of competitive plastic products. Core values Integrity Customer loyalty Continuous improvement Innovation Uncompromising quality
TPM is a philosophy, which brings results when practised. It achieves the optimumuse of resources and obtains best results. Committed to achieve excellence in performance by achieving Zero breakdowns Zero accidents Zero defects with the practice of TPM as a way of life by all employees, throughout the
TPM EQUALSTotal Performance Management through Total Productive Maintenance through Total Perfect Manufacturing by Total employee involvement
TPM starts with 5S. Problems cannot be clearly seen whenthe work place is unorganized. Cleaning and organizing the workplacehelps the team to uncover problems. Making problems visible is the firststep of improvement.
Japanese English Equivalent S term Term Translation Seiri Organisation Sort Seiton Tidiness Systematise Seiso Cleaning SweepSeiketsu Standardisation StandardiseShitsuke Discipline Self - Discipline
Management Indicators Plant Effectiveness Indicators Quality Indicators Energy-Saving Indicators Maintenance Indicators Training and Morale Indicators Safety and Environment
Operating profit Ratio of operating profit to grosscapital Value-added productivity Labour productivity Cost reduction Headcount reduction Reduction in product stock value Reduction in work-in-process value Equipment investment efficiency Plant/Labour ratio
Overall plant effectiveness Overall effectiveness of importantequipment Availability Performance rate Standard production rate Average actual production rate Quality rate Number of equipment (plant) failures Number of process failures
Process defect rate Cost of process defects Number of defects passed on Number of warranty claims Overall yield
Reliability and maintainabilityindicators Maintenance efficiency indicators Maintenance cost indicators Other maintenance indicators
Number of meetings Number of FI topics registered Cost savings due to FI Number of suggestions Number of outside presentations Number of one-point lesson sheets Number of PM trainees Number of official qualificationsacquired
HR ASPECTS OF INDUSTRIALCERTIFICATIONS HR ASPECTS OF TPM MARKETING ASPECTS OFCERTIFIED ORGANISATIONS ETC,