TPM - Supreme

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TPM - Supreme

  1. 1. 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
  2. 2. E.P. JOHNReg. No. 11397044, DMS, SOM
  3. 3. Phase 1 - Introduction Plastics Supreme Industries Ltd. TPMPhase 2 - Supreme TPM Pillars of TPMPhase 3 - Supreme TPM PillarsPhase 4 - Problems Indentified with Probable solutionPhase 5 - TPM Effectiveness Glimpses of TPM practice Conclusion
  4. 4. PLASTICS… Crude Oil (Naphtha) Olefins Aromatics Benzene Ethylene Propylene Butadiene Toluene Xylene
  5. 5.  Easy availability. Low cost in case of massproduction. Low cost as compared to cost ofmetal. Long product life. Resistance to corrosion. Water proofing capability.
  6. 6.  Temperature: barrel zones, tool, die zone Pressures: injection max, hold Times: injection, hold, tool opening Shot size: screw travel Processing window Temp. Thermal degradation Flash Short- shot Melt Pressure
  7. 7.  Pour Short Flashing Sink Marks and Voids Weld Lines Shrinkage
  8. 8.  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.
  9. 9.  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.
  10. 10. INDUSTRIAL PRODUCTS DIVIS
  11. 11. PLASTIC PIPING SYSTE
  12. 12. MAATERIAL HANDLING PRODUCTS DIVISION
  13. 13. MOULDED FURNITURE
  14. 14. PROTECTIVE PACKAGING DIVISION
  15. 15. PLASTIC FILMS DIVISION
  16. 16. SUPREME PETROCHEMOCALS LTD.
  17. 17. SUPREME EXPANDS AND GROWS…
  18. 18.  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.
  19. 19. 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.
  20. 20.  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.
  21. 21. 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%.
  22. 22. 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.
  23. 23.  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
  24. 24. A Safer Workplace Associate Empowerment An Easier Workload Increased Production Fewer Defects Fewer Breakdowns Fewer Short Stoppages (Chokotei) Decreased Costs Decreased Waste (Muda)
  25. 25. STEP B INTRODUCTION STAGE STAGE C IMPLEMENTATION STAGE DINSTITUTIONALISING STAGE
  26. 26. 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
  27. 27. 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
  28. 28. It is aimed to have trouble freemachines and equipments producingdefect free products for total customersatisfaction. Preventive Maintenance Breakdown Maintenance Corrective Maintenance Maintenance Prevention
  29. 29. Prepare QA matrixPrepare production input condition analysis tablePrepare problem chartEvaluate seriousness of problemsUse P-M analysis to track down causes of problemsAssess impact of proposed countermeasuresImplement improvementsReview production – input conditionsConsolidate and confirm check pointsPrepare a quality component control table and assurequality through strict condition control
  30. 30.  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
  31. 31. BUSINESS GROWTH… EFFECTIVE TRAINING + VE GROWT H ORGANISATION WINS THE COMPETITION NORMALTRAINING BUSINESS COMPETITION WINS THE ORGANISATION - VE GROWT H NO TRAINING
  32. 32.  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
  33. 33. 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
  34. 34. 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.
  35. 35. 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
  36. 36. Commitment DenialKick-off ResistanceConsultant IN Aug 2007 Jan 2011 Consultant OU Resistance Exploration
  37. 37.  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
  38. 38. 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
  39. 39. TPM EQUALSTotal Performance Management through Total Productive Maintenance through Total Perfect Manufacturing by Total employee involvement
  40. 40.  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.
  41. 41. Japanese English Equivalent S term Term Translation Seiri Organisation Sort Seiton Tidiness Systematise Seiso Cleaning SweepSeiketsu Standardisation StandardiseShitsuke Discipline Self - Discipline
  42. 42. Pareto DiagramCause & EffectDiagramHistogramControl ChartsScatter DiagramsGraphsCheck Sheets
  43. 43.  Management Indicators Plant Effectiveness Indicators Quality Indicators Energy-Saving Indicators Maintenance Indicators Training and Morale Indicators Safety and Environment
  44. 44.  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
  45. 45.  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
  46. 46.  Process defect rate Cost of process defects Number of defects passed on Number of warranty claims Overall yield
  47. 47.  Electricityconsumption Steam consumption Fuel consumption Water consumption Lubricant/Fluid consumption Auxiliary materials consumption
  48. 48.  Reliability and maintainabilityindicators Maintenance efficiency indicators Maintenance cost indicators Other maintenance indicators
  49. 49.  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
  50. 50.  HR ASPECTS OF INDUSTRIALCERTIFICATIONS HR ASPECTS OF TPM MARKETING ASPECTS OFCERTIFIED ORGANISATIONS ETC,

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