Suggestion Schemes (contd…)

1. Suggestion Schemes (contd…) Prepared by: Bhakti Joshi Date: February 21, 2013

2. Total Productivity Maintenance: Brief Case Study Hindalco manufactures aluminium products in its Renukoot plant in Uttar Pradesh. The plant has significant downtime. A team of workers identified three main reasons for equipment downtime. • Excessive time required for replacement of gaskets in an equipment • Failure of valve resulting in 12 oil-seal replacements in a year • Inappropriate insulation The team realised the problems and eliminated them thus leading to the following: • After eliminating the need for replacing 1,152 gaskets, 3,744 hours of productive machine time was reclaimed • Eliminating oil-seal replacements led to reclaiming 1,536 hours • Developing better insulation at a cost Rs. 1,780 per year, fuel savings worth Rs 4,150 were made and painting cost worth Rs 1,500 per equipment was also avoided Overall, equipment downtime was cut by 87.16% and an annual savings of Rs. 123,000 was also achieved. The entire process was done by an empowered work force, which also perceived job enrichment

3. TPM stands for… • Maintenance and production individuals working together (Total) • Production of goods/services that meet or exceed customers’ expectations (Productive) • Keeping equipment and plant in good or better condition than original condition at all time (Maintenance)

4. Goals of TPM • Equipment capacities maintained and improved always • Aiming towards maintaining equipment for life • Using support from all areas of operation • Encouraging input from all employees • Using teams for continuous improvement

5. TPM concept: Overall Equipment Effectiveness (OEE) OEE = Availability (A) X Performance (E) X Quality (R) ( ) A = (T/P) x 100 A= Availability T = Operating time (P-D) P = Planned operating time D = Downtime E = C x N x 100 E= Performance C = Theoretical cycle time N = Processed amount (quantity) R = N - Q x 100 R= Rate of Quality Q = Non-conformities N = Processed amount (quantity) ( ) N T

6. Example 1 Week 1’s production numbers on machining center JL58 were as follows: • Scheduled operation = 10 hours/day; 5 days/week • Manufacturing downtime due to meetings, material outages, training, breaks and so forth = 410 minutes/week • Manufacturing downtime scheduled and equipment breakdown = 227 minutes/week • Theoretical (standard) cycle time = 0.5 minutes/unit • Production for the week = 4450 units • Defective parts made = 15 units

7. Example 1 (contd…) 3000 minutes / week P = 10 hours/day X 5 days/week X 60 minutes / hour = D = 410 minutes/week + 227 minutes/week = T = (P-D) = C = N = Q = Availability = Performance = Quality = Therefore OEE = 637 minutes / week 2363 minutes / week 0.5 minutes / unit 4450 units 15 units 78.8% 94.2% 99.7% 0.740 or 74%

8. Example 1 (contd…) Week 2’s production numbers on machining center JL58 were as follows: • Scheduled operation = 8 hours/day; 5 days/week • Manufacturing downtime due to meetings, material outages, training, breaks and so forth = 309 minutes/week • Manufacturing downtime scheduled and equipment breakdown = 200 minutes/week • Theoretical (standard) cycle time = 0.5 minutes/unit • Production for the week = 4550 units • Defective parts made = 10 units

9. Example 1 (contd…) 2400 minutes / week P = 8 hours/day X 5 days/week X 60 minutes / hour = D = 309 minutes/week + 200 minutes/week = T = (P-D) = C = N = Q = Availability = Performance = Quality = Therefore OEE = 509 minutes / week 1891 minutes / week 0.5 minutes / unit 4550 units 10 units 0.7879 or 78.79% 1.203 or 120.3% 0.9978 or 99.78% 0.787 * 1.203* 0.997=0.945 or 94.5%

10. Email: bhaktij@gmail.comWebsite: www.headscratchingnotes.net