Total Productive Maintenance (TPM) in Process Industry - ADDVALUE - Nilesh Arora

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TPM Process Industry
by
Best Performing Consulting Organization
Adding Value In Totality !!
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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..

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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

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• Lets go thru the case study of
• Grinding Unit , Kalol

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WHY TPM _at_JKLC, KALOL ???

• To Make Kalol Grinding Unit The Best Grinding
  Unit Among All Cement Companies

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MILE STONES OF JKLC FOR TPM CERTIFICATION
Zone division and cross functional teams prepared
June-2013
Team Building Workshop Arranged Sep. 2013
Rigorous TPM execution started- Oct. 2013
First Internal Audit January-2014
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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.

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PROJECT INITIATION THRU LEAN-TPM Training
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8 PILLARS OF TPM
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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.

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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

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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.

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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

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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

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AUTONOMOUS MAINTENANCE

• 7-Steps of Autonomous Maintenance
• Initial cleaning
• Counter measures
• Provisional checklist
• General inspection and tagging
• Autonomous inspection
• Standardization
• Autonomous management

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INITIAL CLEANING
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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?

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PROVISIONAL CHECKLIST

• Display-Who/What/ When/ How?
• Fix day of the week, time team to do the same
  tagging untagging

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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.

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One Point Lesson
Prepared by .. Approved by . Prepared on
Administered by .
BIDCO Elianto Div
OPL Number
Type Basic Knowledge V-Belts
Wrong
Correct
Vibrating belt indicates that belt is loose
No vibration/oscillation of V belt indicates
proper fit
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AUTONOMOUS MAINTENANCE

• Finally
• Make a AM Board
• Put up 4 things on the board
• Look for list
• Tag graph
• Cleaning Schedule
• OPL

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One Point Lesson
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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)

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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.

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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

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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.

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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.

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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.

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8 PILLARS OF TPM

• J\JKLC\TPM External Audit Level -1\8 pillar doc
  status.xls

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TPM MEASURE 1 OEE

• OEE A factor P factor Q factor
• Availability Factor
• (Run time/ Net operating time)100,
• Calendar time 3024 60 43200 min
• Net operating time Calendar time- (planned
  shutdown no schedule production planned
  maintenance)
• Run time Schedule O.T. - Down time losses

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TPM MEASURE 1 OEE

• Performance Factor
• (Actual O.P/Total O.P)100
• Quality Factor
• (Good O.P/Actual O.P)100

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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

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TPM MEASURE 1 OEE
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TPM MEASURE 2 MTBF
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TPM MEASURE 3 MTTR
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Trainings
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Shop floor Clearing _at_5
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New Bag Filter For Dust Control (Developed
In-House)
Kaizen
Let Us Make Our Plant A Better Plant Every
Moment.
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Fly Ash Unloading System
Kaizen
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 )
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Kaizen
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TEAM BUILDING WORKSHOP
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Glimpse of JKLC Plant
STORES
Before
After
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Glimpse of JKLC Plant
Cement Mill Area
Before
After
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Glimpse of JKLC Plant
Scrap Yard Area
Before
After
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Glimpse of JKLC Plant
Visuals at Shop floor and Lab
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Rewards for TPM Quiz
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Awarded as TPM Certified Organization
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TPM Benefits

• OWNERSHIP RESPONSIBILITY
• EFFECTIVE INVENTORY UTILISATION CONTROL
• BRINGING STAFF CLOSER TO THE MACHINES PROCESSES
• TEAM BUILDING
• ENHANCE PLANT AESTHETICS
• INNOVATIONS GALORE
• OUT OF BOX THINKING

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Road Map -Year 2015

• Lean Certification for implementing
• overall lean tools in organization

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