Post on 13-Jul-2015
transcript
APPLYING TPM(TOTAL PRODUCTIVITY MANAGEMENT) IN
THE RM/PM STORES OF HCCBPL
Step Meaning Benefit
1SSeiri (Sorting)
Identify Unwanted. Sort out Unwanted and Keep in
Designated AreasInventory (I)
2SSeiton
(Arranging)
Scientifically deriving the Right place for an item
Transportation (T), Motion(M), Waiting (W)
3SSeiso (Cleaning)
Defined schedule for cleaning scientifically Defects (D)
4SSeiketsu
(Standardizing)
Preventing the Need for 1s, 2s, 3s Over Production (O), Over Processing (O)
5SShitsuke
(Discipline)Become accustomed to 5s
through repitition and continuity.All the Above
TPM Means 5s Excellence
Can you identify “TIMWOOD” wastes in below Pizza shop:Storage of Packing Material
away from point of use
leading to unnecessary
“Transportation”
Storage of excess
“Inventory” than
currently needed
Unnecessary
“Motion” of Workers
“Waiting” for
Pizza preparation
“Waiting” for Instructions
to transfer Boxes
Unnecessary
“Motion” of Workers
“Over Production”
of Pizzas – two
pizzas against one
consumer
“Over Production”
of Pizzas – two
pizzas against one
consumer
Consumer
“Defects” produced
“Over Processing”
waste – rebaking needed
due to low temperature
The Store Dept. is broadly divided into two categories:
1) Raw Material/Packaging Material/Consumables
2) Engineering SparesMaterial receipt
Material Storage
Material Issue
Record Keeping
Material Order
INTRODUCTION TO STORE DEPARTMENT
Raw MaterialPACKAGING
MATERIALS
CONSUMABLE
Sugar
Concentrate
Alphonso pulp
Totapuri pulp
Preforms
Closures
Crowns
Labels
Sleeves
Cartons
Insert sheet
Lamination
Straws
Salt
Activated carbon
Celite
Hyflo
Dicalite
CYCLE OF THE FUNCTIONAL PROCESS
OF STORES:
STEPS OF PROJECT
Locate stores of RM/PM in the Plant
Measuring dimensions of all the stores & Calculating pallets capacity
Calculating optimal no. of pallets required to store on the basis of lead time & consumption/day of all the lines to prevent stock out
Step2 – Step3 derives the unutilized space .
5s Layout of all RM/PM Stores and proposed Solution to increase Pallet Capacity of Stores.
OLD POP
ASSEMBLY LINES
STORAGE AREA
OTHER AREAS
DRY
PART
LT PANEL
NEW PULP
CONCENTRATE
THAWING
ROOM
BLENDING ROOM
CIP ROOM
NEW LINE STORAGE(ABOVE THE LINE)
PET 40
PET 50
CLOSURE
STORAGE
SLEEVE
STORAGE
LAB
TETRAPACKLINE
TETRAPACK DAY STORAGE
WAREHOUSE
SUGAR STORAGE &
SUGAR MEZZANINE
STORAGE
PET-20
PET-30
WAREHOUSENEW POP
RAW SYRUP ROOM
READY SYRUP ROOM
SUGAR DUMPING ROOM
PET10
OLD POP
CARTON
&W/H CARTON
AREA
WAREHOUSERGB-2
QA
PLANT
OFFICE
CONCENTRA
TE
LABEL
STORE
RGB-MZWTP-1
OLD PULP
STORAGECAUSTIC
TANK
CARB
ON
C-3
C-
2
C-1
C-4
PRODUC
TIONOFFICE
co2
FO & HSD
SALT STOR
E
LPG
OLD LINE AREA
BIB
ROOM
RGB-1
CIP
WTP2
WTP3
BRIQUETTE
BOILER
STORAGE
FRESH
OIL F.O.
BOILEREN
GG.
SPARES STORE DPT.
ETP
RAIN
MAKER
F.O.
BOILERBRIQU
ETTE BOILE
R
SCRAP YARD-1
SCRAP
YARD-2
Step I
Step II
Step III
Speed of one line = 600BPM
Consumption of the Line per Day = 600*60*24
RM/PM per day stored = 600*60*24
To prevent stock out, Optimum requirement of RM/PM to be stored = 600*60*24*Lead time
Optimum requirement of RM/PM are converted into Pallets Required.
Step IV
Unutilized Area of stores
Pallet Capacity of StoreOptimum Requirement of Pallets as per Lead time
and Consumption /Day-
Step V
NEW LINE STORE
PROPOSALS
1) Requirement of PM handling equipment
2) Decrease of issue area
3) Change in space allocation for storage
4) Installation of racks in label area
5) Installation of weight sensitive RFID
6) Executive appointment
7) CCTV camera installation
OLD LINE AREA
• PROPOSALS
1) Racks in closure area
2) Racks in perform area
SUGAR STORAGE/MEZZANINE FLOOR
• PROPOSALS
1) Installation of racks2) Indicators for the crowns3) Better visibility of lot card
SLEEVE/ LABEL/ CLOSURE STORE
• PROPOSALS
1) Installation of pallet flow racks
2) Installation of additional racks
3) Applying Colored Labels
OLD POP/ CARTON STORE
• PROPOSALS
1) Installation of Shrink & stretch machinery & scrap off Carton Machinery
NEW PULP / OLD PULP STORE
TETRAPACK DAY STORAGE
• PROPOSALS
1) Segregation of areas
2) Merging two areas