Dr. T Nambirajan, BE, MBA, PhDHead of the DepartmentDepartment of Management StudiesSchool of ManagementPondicherry University

MY SINCERE THANKS TO…

Mr. Sushil PadhyAssistant General managerIndustrial Products DivisionSupreme Industries Ltd.,Unit – 11, Pondicherry

EFFECTIVENESS OF TPM

@IPD, SUPREME INDUSTRIES LTD.,

PONDICHERRYE.P. JOHN

Reg. No. 11397044, DMS, SOM

Phase 1 - IntroductionPlasticsSupreme Industries

Ltd.TPM

Phase 2 - Supreme TPMPillars of TPM

Phase 3 - Supreme TPM PillarsPhase 4 - Problems Indentified with

Probable solutionPhase 5 - TPM Effectiveness

Glimpses of TPM practice

Conclusion

PLASTICS

Crude Oil(Naphtha)

Olefins

Ethylene Propylene

Butadiene

Aromatics

BenzeneTolueneXylene

PLASTICS…

PLASTICS PROPERTIES…

Easy availability. Low cost in case of mass production. Low cost as compared to cost of metal. Long product life. Resistance to corrosion. Water proofing capability. Better surface finish.

Process Operation

Temperature: barrel zones, tool, die zonePressures: injection max, holdTimes: injection, hold, tool openingShot size: screw travel

Flash

Melt

Thermaldegradation

Short-shot

Temp.

Pressure

Processing window

DEFECTS IN INJECTION MOLDING PROCESS

Pour Short Flashing Sink Marks and Voids Weld Lines Shrinkage

PLASTICS AND ENVIRONMENTALISSUESToxicity

Due to their insolubility in water and inertness pure plastic generally have low toxicity in their finished state.

Plastics pass through the digestive system with no ill effects.

Non-degradability Plastics are very durable and degrade very slowly, the molecular bonds that make plastic so durable make it very much resistant to natural process of degradation.

INJECTION MOULDING MACHINES

COMPANY PROFILE

COMPANY PROFILE

Founded in 1942, Supreme is an acknowledged leader of India's plastics industry. Handling volumes of over 190,000 MT annually. 19 advanced plants are powered by technology from world leaders.Complement extensive facilities for R & D and new product development. Exports remain a focal area of operations.Annual Turnover – Rs. 3,900 Crores in 2010.

INDUSTRIAL PRODUCTS DIVISION

PLASTIC PIPING SYSTEMS

MAATERIAL HANDLING PRODUCTS DIVISION

MOULDED FURNITURE

PROTECTIVE PACKAGING DIVISION

PLASTIC FILMS DIVISION

SUPREME PETROCHEMOCALS LTD.

SUPREME EXPANDS AND GROWS…

TOTALPRODUCTIVE

MAINTENANCE(TPM)

TPM - History

TPM is an innovative Japanese concept. The origin of TPM - when preventive maintenance was introduced in 1951. The concept was taken from USA. Nippon Denso was the first company to introduce plant wide preventive maintenance in 1960.

Total Productive Maintenance

TPM means to achieve high level of

productivity, through total participation of all

people inside the organisation and then developing self

managing abilities in people and practices.

Productivity, in JIPM-TPM means increasing production and reducing

cost simultaneously.

TPM OBJECTIVESAvoiding wastage in a quickly changing economic environment.Producing goods without reducing product quality.Reduce cost.Produce a low batch quantity at the earliest possible time.Goods send to the customers must be non defective.

TPM TARGETSP (Product)Obtain Minimum 80% OPE.Obtain Minimum 90% OEE Run the machines even during lunch. Q (Quality) Operate in a manner, that there are no customer complaints.C (Cost)Reduce the manufacturing cost by 30%.

TPM TARGETSD (Delivery)Achieve 100% success in delivering the goods S (Safety)Maintain a accident free environment.M (Morale)Increase the suggestions by 3 times. Develop Multi-skilled and flexible workers.

STEPS FOR TPM 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

BENEFITS OF TPMA Safer WorkplaceAssociate EmpowermentAn Easier WorkloadIncreased ProductionFewer DefectsFewer BreakdownsFewer Short Stoppages (Chokotei)Decreased CostsDecreased Waste (Muda)

STEP BINTRODUCTION STAGE

STAGE C IMPLEMENTATION

STAGE D INSTITUTIONALISING STAGE

STEPS FOR TPM

FOCUSED IMPROVEMENT

Focused improvement includes all activities that maximise the

overall effectiveness of equipment, processes and plants

through uncompromising elimination of losses and

improvement of performance. Select a topic

Form a project teamRegister the topic

Implement the improvementEvaluate the results

AUTONOMOUS MAINTENANCE

Is geared towards developing operators to be able to take care of small maintenance

tasks.

Step – 0 – Know your equipmentStep – 1 – Initial cleaningStep – 2 – Corrections of abnormalityStep – 3 – Establish cleaning, inspection standardsStep – 4 – Perform general inspectionStep – 5 – Perform process general inspection

PREVENTIVE MAINTENANCE

It is aimed to have trouble free machines and equipments producing defect free products for total customer satisfaction.

Preventive MaintenanceBreakdown MaintenanceCorrective MaintenanceMaintenance Prevention

QUALITY MAINTENANCEPrepare QA matrixPrepare production input condition analysis tablePrepare problem chartEvaluate seriousness of problemsUse P-M analysis to track down causes of problemsAssess impact of proposed countermeasuresImplement improvementsReview production – input conditionsConsolidate and confirm check pointsPrepare a quality component control table and assure quality through strict condition control

EDUCATION AND TRAININGEvaluate the current training program and set policy and priority strategiesDesign a program for improving operating and maintenance skillsImplement operating and maintenance skill trainingDesign and develop a skill-development systemFoster an environment that encourages self-developmentEvaluate the activities and plan for the future

TRAINING

NO TRAINING

EFFECTIVE TRAINING

ORGANISATION WINS THE COMPETITION

COMPETITION WINS THE ORGANISATION

+ VE GROWTH

- VE GROWTH

BUSINESS GROWTH…

NORMALBUSINESS

DEVELOPMENT MANAGEMENTClarify the system’s missionFormulate several alternative proposals capable of fulfilling the missionIdentify criteria for evaluating the system and techniques for quantifying theseEvaluate the proposalsDocument the analytical results and processes

———————————————————

Target line

conventional picture

conventional picture

Overall equipment efficiency

Start-up period

Full-scale operation

immediately after start-up

Full-scale operation

immediately after start-up

N

o. o

f min

or d

efec

tsO

vera

ll eq

uipm

ent e

ffici

ency

(%)

No. of minor defects

0 0

N

o. o

f min

or d

efec

tsO

vera

ll eq

uipm

ent e

ffici

ency

(%)

———————————————————

Overall equipment efficiency

Start-up period

Target line

———————————————————

Target line

conventional picture

conventional picture

Overall equipment efficiency

Start-up period

Full-scale operation

immediately after start-up

Full-scale operation

immediately after start-up

N

o. o

f min

or d

efec

tsO

vera

ll eq

uipm

ent e

ffici

ency

(%)

No. of minor defects

0 0

N

o. o

f min

or d

efec

tsO

vera

ll eq

uipm

ent e

ffici

ency

(%)

———————————————————

Overall equipment efficiency

Start-up period

Target line

———————————————————

Target line

conventional picture

conventional picture

Overall equipment efficiency

Start-up period

Full-scale operation

immediately after start-up

Full-scale operation

immediately after start-up

N

o. o

f min

or d

efec

tsO

vera

ll eq

uipm

ent e

ffici

ency

(%)

No. of minor defects

0 0

N

o. o

f min

or d

efec

tsO

vera

ll eq

uipm

ent e

ffici

ency

(%)

———————————————————

Overall equipment efficiency

Start-up period

Target line

Development Management and Start-up Period

SAFETY, HEALTH AND ENVIRONMENT

Establish basic safety requirements through,Step – 1 Detect and correct any problems that might affect safety or the environment.Step – 2 Improve safety and environment by eliminating sources of leaks, spills and dust.Step – 3 Establish individual safety routines.

OFFICE TPM

The five core activities for 0ffice TPMIncrease work efficiency through focused improvementBuild a system of administrative autonomous maintenanceImprove administrative capacity through education and trainingCreate an efficient staffing systemDevelop a work evaluation system

SUPREME TPM

TRANSITION CURVE

Denial

Kick-offConsultant IN

Resistance

ResistanceConsultant OUT

Exploration

Commitment

Aug 2007 Jan 2011

SUPREME TPMVision - To grow business with dignity and respect

Mission - To retain a world-class manufacturer of competitive plastic

products.

Core values IntegrityCustomer loyaltyContinuous improvement

InnovationUncompromising qualityEmpowerment to individuals

SUPREME TPM POLICYTPM is a philosophy, which brings results when practised. It achieves the optimum use of resources and obtains best results. Committed to achieve excellence in performance

by achievingZero breakdowns

Zero accidentsZero defects

with the practice of TPM as a way of life by all employees, throughout the

organisation.

Total Performance Managementthrough

Total Productive Maintenancethrough

Total Perfect Manufacturingby

Total employee involvement

TPM EQUALS

5S

TPM starts with 5S. Problems cannot be clearly seen when the work place is unorganized. Cleaning and organizing the workplace helps the team to uncover problems. Making problems visible is the first step of improvement.

5S

Japanese

Term

English

Translation

Equivalent 'S'

term

Seiri Organisation Sort

Seiton Tidiness Systematise

Seiso Cleaning Sweep

Seiketsu Standardisation Standardise

Shitsuke Discipline Self - Discipline

THE 7 QC TOOLSPareto Diagram Cause & Effect Diagram Histogram Control Charts Scatter Diagrams Graphs Check Sheets

TPM EFFECTIVENESS

TPM EFFECTIVENESSManagement IndicatorsPlant Effectiveness IndicatorsQuality IndicatorsEnergy-Saving IndicatorsMaintenance IndicatorsTraining and Morale IndicatorsSafety and Environment

MANAGEMENT INDICATORSOperating profitRatio of operating profit to gross capitalValue-added productivityLabour productivityCost reductionHeadcount reductionReduction in product stock valueReduction in work-in-process valueEquipment investment efficiencyPlant/Labour ratio

PLANT EFFECTIVENESS INDICATORS

Overall plant effectivenessOverall effectiveness of important equipmentAvailabilityPerformance rateStandard production rateAverage actual production rateQuality rateNumber of equipment (plant) failuresNumber of process failures

QUALITY INDICATORSProcess defect rateCost of process defectsNumber of defects passed onNumber of warranty claimsOverall yield

ENERGY-SAVING INDICATORS

Electricity consumptionSteam consumptionFuel consumptionWater consumptionLubricant/Fluid consumptionAuxiliary materials consumption

MAINTENANCE INDICATORS

Reliability and maintainability indicatorsMaintenance efficiency indicatorsMaintenance cost indicatorsOther maintenance indicators

TRAINING AND MORALEINDICATORS

Number of meetingsNumber of FI topics registeredCost savings due to FINumber of suggestionsNumber of outside presentationsNumber of one-point lesson sheetsNumber of PM traineesNumber of official qualifications acquired

FURTHER SCOPE OF STUDY

HR ASPECTS OF INDUSTRIAL CERTIFICATIONSHR ASPECTS OF TPMMARKETING ASPECTS OF CERTIFIED ORGANISATIONS ETC,

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