Why TPM in Process Industry? - ADDVALUE - Nilesh Arora

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Training on Why Total Productive Maintenance (TPM) in Process Industry presented by Nilesh Arora, a founder of AddValue Consulting Inc.

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Presentation Transcript

Slide1:

Best Performing Consulting Organization by “TPM – Process Industry” Adding Value In Totality !!

PROCESS INDUSTRY MEANS??:

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..

WHY TPM IN PROCESS INDUSTRY ?:

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”

Slide4:

Let’s go thru the case study of Grinding Unit , Kalol

WHY TPM @JKLC, KALOL ???:

WHY TPM @JKLC, KALOL ??? “To Make Kalol Grinding Unit The Best Grinding Unit Among All Cement Companies”

MILE STONES OF JKLC FOR TPM CERTIFICATION:

MILE STONES OF JKLC FOR TPM CERTIFICATION Second Internal Audit November – 2014 Cleared Audit of TPM Level-1 December -2014 First Internal Audit January-2014 Rigorous TPM execution started- Oct. 2013 Team Building Workshop Arranged Sep. 2013 Zone division and cross functional teams prepared June-2013 Kicked off TPM with consultant Aprill-2013

WHAT IS TPM??:

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.

PROJECT INITIATION THRU LEAN-TPM Training :

PROJECT INITIATION THRU LEAN-TPM Training

8 PILLARS OF TPM:

8 PILLARS OF TPM

FOCUSED IMPROVEMENT:

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.

AUTONOMOUS MAINTENANCE:

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

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. AUTONOMOUS MAINTENANCE

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 AUTONOMOUS MAINTENANCE

JKLC First 10 months only & only COT:

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

AUTONOMOUS MAINTENANCE:

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

INITIAL CLEANING :

INITIAL CLEANING

COUNTER MEASURES:

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?

PROVISIONAL CHECKLIST:

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

OPL – One Point Lesson:

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.

Slide24:

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

AUTONOMOUS MAINTENANCE:

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

One Point Lesson:

One Point Lesson

PLANNED MAINTENANCE:

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)

TRAINING AND EDUCATION:

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.

EARLY MANAGEMENT:

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

QUALITY MAINTENANCE:

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.

OFFICE TPM:

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.

SAFETY, HEALTH AND ENVIRONMENT:

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.

8 PILLARS OF TPM:

8 PILLARS OF TPM J:\JKLC\TPM External Audit Level -1\8 pillar doc status.xls

Slide34:

OEE= A factor * P factor * Q factor Availability Factor = (Run time/ Net operating time)*100, Calendar time = 30*24* 60 = 43200 min Net operating time = Calendar time- (planned shutdown+ no schedule production + planned maintenance) Run time = Schedule O.T. - Down time losses TPM MEASURE: 1 OEE

Slide35:

Performance Factor = (Actual O.P/Total O.P)*100 Quality Factor= (Good O.P/Actual O.P)*100 TPM MEASURE: 1 OEE

Slide36:

MTBF(Mean time between failure) = Total running time /Number of breakdowns TPM MEASURE: 2 MTBF TPM MEASURE: 3 MTTR MTTR(Mean time to repair) = Total down time /Number of breakdowns

Slide37:

TPM MEASURE 1: OEE

TPM MEASURE 2: MTBF:

TPM MEASURE 2: MTBF

TPM MEASURE 3: MTTR:

TPM MEASURE 3: MTTR

Trainings:

Trainings

Shop floor Clearing @5:

Shop floor Clearing @5

New Bag Filter For Dust Control (Developed In-House):

Let Us Make Our Plant A Better Plant Every Moment. New Bag Filter For Dust Control (Developed In-House) Kaizen

Fly Ash Unloading System:

One Truck Unloading Time - 14- 16 Minutes (Qty -17 Ton) Benefits: 1. Power Saving 2. Effective fleet utilization 3. Effective Plant Area Utilization ( Parking ) Two Trucks Unloading Time - 18- 21 Minutes (Qty -34 Ton) Three Trucks Unloading Time - 40- 45 Minutes (Qty -51 Ton) Fly Ash Unloading System Kaizen

Kaizen:

Kaizen

TEAM BUILDING WORKSHOP:

TEAM BUILDING WORKSHOP

Glimpse of JKLC Plant :

Glimpse of JKLC Plant STORES Before After

Slide48:

Before After Cement Mill Area Glimpse of JKLC Plant

Slide49:

Before After Scrap Yard Area Glimpse of JKLC Plant

Slide50:

Visuals at Shop floor and Lab Glimpse of JKLC Plant

Rewards for TPM Quiz:

Rewards for TPM Quiz

Awarded as TPM Certified Organization:

Awarded as TPM Certified Organization

TPM Benefits:

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

Road Map -Year 2015 :

Road Map -Year 2015 Lean Certification for implementing overall lean tools in organization

ADDVALUE Services:

ADD VALUE Services VALUE ADDED COACHING-VAC ® BUSINESS COACHING LIFE COACHING Operation Excellence Team Excellence Business Excellence Counselling Therapy Astrology Adding Value In Totality !!

Slide56:

Best Performing Consulting Organization Add Value at a glance Business Coaching Life Coaching

Thank You:

Thank You

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