CASE STUDY ON:HINDUSTAN LEVER LIMITED(SUBJECT: PRODUCTIONS AND OPERATIONS MANAGEMENT)Prepared by :• Asit Dholakia• & Team
HISTORY Hindustan Vanaspati Manufacturing, first Indiansubsidiary set up in 1931 Lever Brothers India Limited set up in 1933 United Traders Limited set up in 1935 All 3 companies merged to form HLL in 1956 The Anglo-Dutch company Unilever owns a majoritystake in Hindustan Unilever Limited.(owns a 52% majority stake.) Renamed In June 2007 as Hindustan Unilever Ltd.
PLANTS ACCLAIMED WITH AWARD Japan Institute of Plant Maintenance [JIPM] Honored its JIPMexcellence awards on Hindustan Lever Limited’s (HLL) Plants Sumerpur, Chhindwara, Yavatmal [Personal products] Silvassa [Personal Products]
PLANTS PRODUCTS & PRODUCTION CAPACITY Dadra & Amli Villages Near Silvassa are home to the twopersonal Products Factories Of HLL Dadra unit Has Production Capacity Of 5000 tones perannum (tpa) and the Amli unit has a capacity of 18000 tpa. The products Manufactured in these factories include: fairness creams(fair & lovely), Lotions, Shampoos (Clinic All Clear, Sunsilk- both bottles & sachets), Deodorants, Talcs (denim) & Toothpaste (Pepsodent)
WORN-OUT MACHINE PARTS At the silvassa Factories of HLL, the Worn out Machine partsare not tossed out to the trash like other factories does. The Workers collect These failed parts Carefully. Formal Records of such parts are Maintained by the WorkersAnd these parts are stored in a specially Created ‘Museum’
AT SILVASSA FACTORIES OF HLL:-• WORN-OUT MACHINE PART• FORMAL RECORDS• STORED AT MUSEUM
PURPOSE SERVED BY THESE PART ARE• UNDERSTAND WRONG THINGS• MODIFICATION OF DESIGNING• REDUCE CHANGEOVER TIME• DISPLAY BOARD SYSTEM
DISPLAY BOARD SYSTEM• A CROSS• FIND TRAINERIN CASE OF NEW MACHINE
TOTAL PRODUCTIVE MAINTENANCE Maintenance management is planning,organizing, and controlling maintenanceactivities such that the overall maintenancecost is the minimum.
Why we need TPM ? The major objectives of the TPM arelisted as under :1. Avoid wastage in quickly changingenvironment.2. Reduce Cost of Manufacturing3. Goods send to Customers must be“ non – defective”
TYPES OF MAINTENANCE Breakdown maintenance Preventive maintenance
Benefits of TPM: Less breakdowns. Life of equipment increases. Production cost can be minimize. Qualities of production can be improve. Reducing accidents. Higher confidence level among the workers. Rectify customers complaints. Keep the work place clean, neat and attractive.
TPM COSTS AND BENEFITS OVER THE PASTTHREE YEARS AT HLLManufacturing site Investment(Rs million)Benefits(Rs million)Silvasa 15.00 210.00Chhindwara 8.00 24.00Yavatmal 6.00 60.00Orai 4.50 60.00Raipura 4.20 62.00Mangalore 6.20 111.00Daman 10.0 139.00sumerpur 2.00 23.00
1. Autonomous maintenance.2. Individual improvement.3. Planned maintenances.4. Quality maintenance.5. Development management.6. Education and training.7. Safety, health & development.8. TPM in office.THE EIGHT PILLAR OF TPM
FOUR LEVELS To the TPM factory organizational structure atthe HLL, there is mainly 4 levels are workingwhich are, At top the corporate TPM steering committeeheaded by HR director. At the next level there is a group comprising thetechnical head of HLL, corporate qualityassurance and the TPM head and factory Head.
CONTINUE…. Below this level pillar heads are working. At the lowest level there are TPM circle composedby workers and headed by an officer of HLL. Eachcircle has unique name and identity.
CONCLUSION TPM technique is very beneficialto the Company. Enthused with the Results ofTPM implementation, HindustanLever Limited management hasdecided to implement thisinitiative at every strategic siteand all new factories, includingUniliver Factories in the region.