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