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…………………Company Survives
4. We eliminate all losses in the resources and energy to conserve the Earth’s
environment.
Breakdown
ZERO Defect
Accidents
Losses
Development management
Pune
Autonomous
TPM
Maintenance
TPM in Offices
Japanese
English Translation Equivalent 'S' term
Term
BEFORE AFTER
BEFORE AFTER
BEFORE AFTER
Support PM Pillar
• CBM of Q Components.
• QM Matrix
• Defect Analysis using different tools.
• Q Components.
• Implementing Defect Elimination Projects.
• CBM of Q Components for easy
• Sustenance and Reliability Enhancement.
Inspection
• Reduction of Inspection / Sampling Cost.
• Skill Assessment
• Identifying Training Needs for achieving
business objective.
Skill /
• Imparting Training / OJT / External Knowledge
happenings in the market. Improvement
• Review the skill level and if not okay
retrain.
• Continuous Monitoring.
Support by PM Pillar
Upgraded Skill level for
achieving Business Objective
“Best Practices in Maintenance Management”
May 11, 2010. Pune 22
Key Activities
Cost Awareness /
Cost Effective Programs.
“Best Practices in Maintenance Management”
May 11, 2010. Pune 23
Key Activities
Purpose :
Functions of equipment can be
demonstrated satisfactorily
whenever equipmentcost.
needs them at minimum
Failure
Ranking of Equipment
Support to JH
Sustenance Activities
34%
A
53% B
1 A Critical 34% 27
2 B Moderate 53% 42
Total machines 79
Inadequate basic
conditions
Lack of skills
Leaving
deterioration
unrepaired
Design
shortcomings
Non-observance
of usage conditions
Why rod has scratch Chips were scattered and Measures taken to prevent chips
attached to rod from scattering
Why chips were Cylinder located within scattering Cylinder’s position changed and
attached to rod range of chips and rod cover is cover fixed
not placed
Why cylinder located Defective design and installation Standardise design and installation
within scattering range of
chips and rod cover not
replaced
“Best Practices in Maintenance Management”
May 11, 2010. Pune
Area wise Stratification of Phenomena's
Total Phenomenon:94
Electronics,
14
Electrical, 25 Mechanical,
55
10 12 51 Hydraulic System
18
22 Auto Tool Changer
32 Axis
20
Rubber sheet
19 18
Coolant
Spindle
Table
63 72 Lubrication
Air leakage
Burr
41 36
Door
No root CBM, 1
cause, 8
Training, 17
Kaizen, 39
Preventive
Maintenance,
46
“Best Practices in Maintenance Management”
May 11, 2010. Pune
Development of PM module
1500
1200 BETTER
1200
Nos of Hours
4
90
900
3
72
0
66
1
62
61
2
0
55
54
600
5
5
42
42
5
0
30
4
30
28
4
24
0
300
21
2
11
0
0
B.M. Apr- May- Jun- Jul-07 Aug- Sep- Oct- Nov- Dec- Jan- Feb- Mar- Apr- May- Jun- Tgt
( Oct-06 to Mar-07 ) 07 07 07 07 07 07 07 07 08 08 08 08 08 08
333
300 BETTER
Occ. In Nos
5
20
200
5
15
5
14
14
5
5
12
12
0
12
4
4
11
11
2
10
99
85
100
65
55
12
0
0
B.M. Apr- May- Jun-07 Jul-07 Aug- Sep- Oct-07 Nov- Dec- Jan-08 Feb- Mar- Apr- May- Jun-08 Tgt
( Oct-06 to Mar-07 ) 07 07 07 07 07 07 08 08 08 08
3 BETTER
Percentage of sales
33 % DOWN
2.1
2
1.6
1.2
0
B.M. Tgt Actual Jun 08
NOT OK NOT OK
LSL OK USL OK
LSL USL OK
LSL USL
WHO Men Day shift, night shift, new employees, temporary help
WHAT Materials Lots, type No.
WHERE Location Part, range, process, equipment
WHICH Trend Direction (+, -, fore, rear, left and right), increase, reduction
HOW Status Equipment, jigs,tools, accuracy (dynamic, stationary), machining conditions
Benefits:
1)Machine availability improved.
Analysis: Result: Door speed setting time
reduced
Why1: Door speed Setting time more 100
Why2: Guard has to removed for
setting. How to Sustain : Irreversible
Time in Min.
DESPATCH
INVENTORY
PRODUCTION
JH
KK KK KK KK QM QM
PM
MANUFACTURING COST
FIXED VARIABLE
CONS
R/W B/D
LOL OML UM
HRS
PM PM
KK KK QM
Allen key
Allen key
DATE EXECUTED
TEACHER
STUDENT
• Kaizen ( Countermeasure)
Development Management • Design Review Meeting
Office TPM • Cost, Lead time reduction, Quality
• Purchasing department – Advising to supplier ( Quality, TPM)