TPM Process Industry

by

Best Performing Consulting Organization

Adding Value In Totality !!

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 ?
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

Lets go thru the case

study of
Grinding Unit , 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
Zone division and
cross functional
teams prepared
June-2013
Team Building
Workshop
Arranged Sep. 2013

Kicked off TPM

with consultant
Aprill-2013

Rigorous TPM
execution startedOct. 2013

Second Internal
Audit
November 2014
First Internal Audit
January-2014
Cleared Audit of
TPM Level-1
December -2014

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

8 PILLARS OF TPM

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
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
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

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

INITIAL CLEANING

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

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.

One Point
Lesson

BIDCO
Elianto Div

Prepared by: .. Approved by .

Prepared on: Administered by .

Type: Basic Knowledge: V-Belts

Wrong

Vibrating belt indicates

that belt is loose

OPL Number:

Correct

No vibration/oscillation of
V belt indicates proper fit

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

One Point Lesson

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

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 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 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 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
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
J:\JKLC\TPM External Audit Level -1\8 p
illar doc status.xls

TPM MEASURE: 1 OEE

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)

TPM MEASURE: 1 OEE

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

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

TPM MEASURE 1: OEE

1.20

1.00
0.86
0.80 0.82

1.03
1.00 0.98 1.01
0.99
0.98
0.97
0.96
0.95 0.93 0.97 0.96 0.94
0.94 0.94 0.92
0.94 0.95
0.94 0.94
0.92
0.91
0.91 0.93
0.91
0.90
0.89
0.88
0.88
0.87 0.85 0.87
0.87 0.88
0.87
0.86
0.85 0.85
0.84 0.84
0.84
0.82

0.72
0.72

0.60

OPC
Exponenti
al (OPC)

0.40

PPC

0.20

0.00
41306
41365
41426
41487
41548
41609
41671
41730
41791
41852
41926
41275
41334
41395
41456
41518
41579
41640
41699
41760
41821
41896
41957

TPM MEASURE 2: MTBF

Clutch Jam
Pinion Bearing

567 gb1 lppb operate

Torsion Shaft

567 BE1
CA Fan

Mill i/l oil Pr. Low

Main Drive Fault
480

60
600

480
360
240
240

360

480

240
60
240
120
120
120
120
120
120

120

120
120
120
APR-2013 TO JUL-2013

240
240

240

120
360
120
120

24
360

240

240

120
240

360

AUG-2013 TO NOV-2013

DEC-2013 TO MAR-2014

120
600

360
240
240

360

120

120

120
360
480

APR-2014 TO JUL-2014

240
60
600

AUG-14 TO NOV-14

TPM MEASURE 3: MTTR

650
550
450
350
250
150
50
-50

Clutch
Jam
567 gb1
lppb
operate
567 BE1
Mill i/l oil
Pr. Low
Pinion
Bearing
Torsion
Shaft
CA Fan
Main
Drive
Fault

Trainings

Shop floor Clearing @5

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

Let Us Make Our Plant A Better Plant Every

Moment.

Kaizen
Fly Ash Unloading System
One Truck Unloading Time - 14- 16 Minutes (Qty
Two
Trucks Unloading Time - 18- 21 Minutes (Qty
-17 Ton)
Three
Trucks Unloading Time - 40- 45 Minutes (Qty
-34 Ton)
-51 Ton)

Benefits: 1. Power Saving

2. Effective fleet utilization
3. Effective Plant Area Utilization ( Parking )

Kaizen

TEAM BUILDING WORKSHOP

Glimpse of JKLC
Plant
STORES
Before
After

Glimpse of JKLC Plant

Cement Mill Area
Before
After

Glimpse of JKLC Plant

Scrap Yard Area
Before
After

Glimpse of JKLC Plant

Visuals at Shop fl oor and Lab

Rewards for TPM Quiz

Awarded as TPM Certified

Organization

TPM Benefits
1. OWNERSHIP & RESPONSIBILITY
2. EFFECTIVE INVENTORY UTILISATION &
CONTROL
3. BRINGING STAFF CLOSER TO THE
MACHINES & PROCESSES
4. TEAM BUILDING
5. ENHANCE PLANT AESTHETICS
6. INNOVATIONS GALORE
7. OUT OF BOX THINKING

Road Map -Year 2015

Lean Certification for
implementing
overall lean tools in
organization

ADDVALUE Services
VALUE ADDED COACHINGVAC
BUSINESS
COACHING
Operation
Excellenc
e
Team
Excellenc
e
Business
Excellenc
e

LIFE COACHING
Counsellin
g
Therapy

Adding Value In
Totality !!

Astrology

AddValue at a glance
Best Performing Consulting Organization

Business Coaching

Life Coaching

Thank You