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Manish engg ppt 26.04.16
- 1. TPM – Way Towards Manufacturing Excellence MANISH ENGINEERING WORKS dtj1 Welcomes All MANISH ENGINEERING WORKS K-161, L-33 , MIDC, Waluj, Aurangabad Vendor Code – CNM0034 Unit - I Unit - II
- 2. TPM – Way Towards Manufacturing Excellence MANISH ENGINEERING WORKS dtj2 Introduction • Name: Mr. Manish Rawke • Education: B.E. Mechanical, MIE, Chartered Engineer • Work Experience: Greaves Cotton Ltd. (4 Years) • Department: R & D • Nature of Work: Design of products, Manufacturing process , Prototype sample to Mass Production • Firm: Manish Engineering Works established in 1999 at MIDC Waluj, A’Bad • Initial Set up: Mechanical presses from 10 to 50 tons ( 6 Press) • Products: Clamps, Levers, Washers, Brackets & Fabrication Work. • Customers: Greaves, Videocon & Marathwada Auto
- 3. TPM – Way Towards Manufacturing Excellence MANISH ENGINEERING WORKS dtj3 In 2001-02, • Supply starts for MS and Bakelite Washers, Brackets, and Assembly work. • Got new orders of Fabrication work & Sub assemblies. In 2002-03, • OLC Assemblies Started (Mounting Bracket Assy. & Drive Shaft Assy. For Wiper motor). In 2003-04, • To avoid logistic loss & Mfg. Lead Time OLC Assemblies Converted with Material (Mounting Bracket Assy. & Drive Shaft Assy. For Wiper motor). • Got opportunity for Pulsar Yoke Development on Conventional Lathe ( Component Requirement). With special expanding mandrel achieved run out of spigots in 50µ w.r.t ID. • Process approved & appreciated by BAL Team & Production Starts. • After change in design of Yoke, First CNC installed
- 4. TPM – Way Towards Manufacturing Excellence MANISH ENGINEERING WORKS dtj4 Our Products
- 5. TPM – Way Towards Manufacturing Excellence MANISH ENGINEERING WORKS dtj5 Group Revenue Sales in Cr. Projected
- 6. TPM – Way Towards Manufacturing Excellence MANISH ENGINEERING WORKS dtj6 Customer View • In-Consistency in Quality • Delivery failures • Repeated customer complaints • Delay in Development Management View • Reduction in Production losses • Reduction in Cost loss • Achieve Zero Breakdown, Zero Accident, Zero Defect • Low WIP Inventory • Development Lead Time Reduction Team View • Only Fire fighting, Production & Dispatch any how? • Reactive approach • Lack of discipline • No CFT working • System for Sustenance • Competent Frontline Initial Challenges
- 7. TPM – Way Towards Manufacturing Excellence MANISH ENGINEERING WORKS dtj7 • Cell Level Ownership of Profit Centre • Cross Functional Team Working • Ensure Targeted Profit • Satisfied Customer • Optimum Utilization of 4M1T Resources • Basic Restoration • Reactive & Proactive Improvements • Sustenance • Excellence • Cell Concept • Unidirectional Material Flow • Single Piece Flow • Pull System • Operation with Reduced WIP • Online Control Streamline Mfg. System SMS Total Productive Maint. TPM Lean Mfg.Lean Methodology
- 8. TPM – Way Towards Manufacturing Excellence MANISH ENGINEERING WORKS dtj8 • Cell Concept • Unidirectional Material Flow • Single Piece Flow • Pull System • Operation with Reduced WIP • Online Control Streamline Mfg. SystemSMS Approach – Phase I QQ Final Inspection Dispatch
- 9. TPM – Way Towards Manufacturing Excellence MANISH ENGINEERING WORKS dtj9 Approach – Phase I HMSI Cell
- 10. TPM – Way Towards Manufacturing Excellence MANISH ENGINEERING WORKS dtj10 • Optimum Utilization of 4M1T Resources • Basic Restoration • Reactive & Proactive Improvements • Sustenance • Excellence Total Productive Maint.TPM Approach – Phase II
- 11. TPM – Way Towards Manufacturing Excellence MANISH ENGINEERING WORKS dtj11 OEE Loss Capturing TPM Track System Capturing Machine wise Losses TPM Track System Capturing 16 Loss Data Loss Analysis Identify Loss for Improvement Countermeasure on Losses Kaizen Idea Horizontal Deployment
- 12. TPM – Way Towards Manufacturing Excellence MANISH ENGINEERING WORKS dtj12 OEE – HMSI Cell 90 80.4 80.7 81.3 82.7 83.6 85.83 50 55 60 65 70 75 80 85 90 95 100 BM (Nov-15) Dec-15 Jan-16 Feb-16 Mar-16 Apr-16 May-16 Jun-16 Jul-16 Aug-16 Sep-16 Oct-16 Nov-16 Dec-16 Target OEE % (HMSI) BM OEE Target
- 13. TPM – Way Towards Manufacturing Excellence MANISH ENGINEERING WORKS dtj14 Key Initiative for Zero PPM - Prevention of Customer Complaint Customer Complaint - Methodology Study Product Drawing To identify CTQ Points InspectionAgreement with Customer To Know importance of: • Fitment • Functional • Aesthetic Parameters & inspection frequency with checking method. Prepare Final Inspection Check Sheet Facilities at Final Inspection Stage • Inspection Table • Gauges (in line with Customer) • Place for gauges • Lights with illumination level • Display Document • Reference samples OK / Not OK • Red lockable bin for not Ok • Monitor Records for arrested defect Skilled Inspector • Train Inspector with OJT • Give Ownership • Monitor Performance as Zero Customer Complaint • Contribute for Corrective action
- 14. TPM – Way Towards Manufacturing Excellence MANISH ENGINEERING WORKS dtj15 IHR Methodology Defect Phenomenon Killed Key Initiative for Zero PPM – Elimination of In-house Rejection MakeKaizens & Pokayokefor arresting the defects at source C Type Defect • Processnot ok, (while initial setup) correctiveaction taken. • Processbecome ok, jobsok MakeKaizens & Pokayokefor identified causes Capture Defect Phenomena of the Process Categorizedefectinto A, B & C Type Wise PrepareQA Matrix to understand the generating point Analyzeby doing FTA Approach, identify 4M1TCondition MakeSustenance plan for ensuring zero defectstatus with help of QMMatrix Analyzeby doing Why Why Analysis A Type Defect • ProcessOK, in between not ok comes, • causes is known action taken process becomesok B Type Defect • Processok, suddenly not ok comes • Cause not known, no action taken yet next job ok IHR – HMSI Cell 8 3 2 3 5 2 1 2 0 1 2 3 4 5 6 7 8 9 Total Defect A Type B Type C Type Mar. 15 Mar. 16 33378 145073 830 260 0 20000 40000 60000 80000 100000 120000 140000 160000 Jun. 15 (Past) Mar. 16 (Present) Suppled Qty. IHR PPM
- 15. TPM – Way Towards Manufacturing Excellence MANISH ENGINEERING WORKS dtj16 IPO - Methodology Control Plan Sustenance of In-house Rejection • To understand ‘I’ Dimensions • To identify CTQ Points Study Drawing QM Matrix (Control Plan / IPO Doc.) IPO Linkage to Check Sheet Follow Activities as per Control Plan / IPO • Work on Abnormalities Monitor Result • If not OK • Revisit IPO Document • Revisit 4M1T Condition • JH / PM / Tool Fix. Maint / Process Quality / Material Handling / SOP / Gauges Calibration QAMatrix• Happen and May Happen Study : Defect Possibilities Corr.Action on happen & May happen Defects • Cause Side Action: - Kaizens - Pokayoke • Insp. Side Action: - Q Alerts - Check Points / OPL - Process Parameter
- 16. TPM – Way Towards Manufacturing Excellence MANISH ENGINEERING WORKS dtj17 P Q Plant PQCDSM Result
- 17. TPM – Way Towards Manufacturing Excellence MANISH ENGINEERING WORKS dtj18 D S M Plant PQCDSM Result
- 18. TPM – Way Towards Manufacturing Excellence MANISH ENGINEERING WORKS dtj19 Recognition by Varroc CII Kaizen Competition - 2014 2014 IVKC - 2013 Achievements
- 19. TPM – Way Towards Manufacturing Excellence MANISH ENGINEERING WORKS dtj20 We have celebrated this moment with our employees Recognition For Front Line
- 20. TPM – Way Towards Manufacturing Excellence MANISH ENGINEERING WORKS dtj21 Progress – Cell Formation HMSI CellREML Cell Crank Pin Cell BSC CellYoke Cell
- 21. TPM – Way Towards Manufacturing Excellence MANISH ENGINEERING WORKS dtj22 Challenges FY 2015-16 • Development lead time high • High In-house Rejection • Start up delay • Product cost high • High Investment in same category To develop the Component: • With minimum lead time • To ensure product functions as well as to achieve: “Ease of Quality assurance” “Ease of Manufacturing” “Achieve Vertical start-up during volume production” • To meet the anticipated needs of Users/ Customer • Capacity enhancement by productivity improvement & by addition of new machines Background Aim
- 22. TPM – Way Towards Manufacturing Excellence MANISH ENGINEERING WORKS dtj23 No. Challenges Activity 1 Sustenance of In-House Rejection • Implementation of IPO With Daily Work Management 2 Minimum Development Lead Time • Implementation of MP Generation System & Used while NCDS 3 Fast Ramp up volume • Capacity enhancement by Production per hour improvement with existing set up & • By Addition of new machine 4 Elimination of Non value added activity • Small Automation • Multi - Gauging • Process upgradation 5 Manpower Retention • Empowerment of Frontline Team • Fatigue free Processes • Healthy Work Environment Forecast Challenges FY 2016-17
- 23. TPM – Way Towards Manufacturing Excellence MANISH ENGINEERING WORKS dtj24 Future Approach – Phase III DWM Approach: Benefits:
- 24. TPM – Way Towards Manufacturing Excellence MANISH ENGINEERING WORKS dtj25 Thanks for Timely Support & Guidance by Journey Continues… dtj Team&Team