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Feb '02 P N Patankar - CQP 1

COST MANAGEMENT

through

TOTAL PRODUCTIVE MAINTENANCE

One Day Awareness

Programme

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Feb '02 P N Patankar - CQP 2

Time Panning

• I Session !"#$! % &&#!!

• Tea 'rea( &&#!! % &&#)!

• II Session &&#)! % !&#!!

• Lun*h !&#!! % !&#+,

• III Session !&#+, % !$#&,

• Tea 'rea( !$#&, % !$#$,• IV Session !$#$, % !+#&,

• Summarising !+#&, - !+#$!

• .uestion % Answer !+#$! % !,#!!

• /ee01a*( Sheet !,#!! % !,#&!

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Feb '02 P N Patankar - CQP 3

 Present S*enario

• /oreign Com2etition

• Instae0 Ca2a*ity Greater than Deman0

• .uaity is 'asi*

• Seing Pri*e is Di*tate0 1y Mar(et

• Seing Pri*e is /aing

• Raw Materia Pri*e is Di*tate0 1y Mar(et

• Pro3it is Un0er Pressure

  De2en0ent

  Pro3it

TPM is an E33e*ti4e Too /or Re0u*ing Costs

Con4ersion Cost

 

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Feb '02 P N Patankar - CQP 4

5hat is TPM 6

• TPM Aims at

 – Dou1ing Pro0u*ti4ity – Re0u*e Chroni* Losses to 7ero

 – Create 'right8 Cean 9 Peasant /a*tory

• Im2ro4es Pro0u*t .uaity

• Im2ro4es E:ui2ment ;eath

•  Creates Parti*i2ation o3 a Em2oyees

• Creates a Metho0 o3 Cas*a0ing Organisation<s

O1=e*ti4es

• It is a Ste2 1y Ste2 A22roa*h

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Feb '02 P N Patankar - CQP 5

The Eight Ma=or Losses

Startu2 .uaity De3e*t Re2ro*essing

Re0u*e0 Rate Changeo4er  

Ca2a*ity

  'rea(0own

  Time

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Feb '02 P N Patankar - CQP 6

&# Panne0 Maintenan*e

A4aia1iity

)# Pro0u*tion Contro > ?Caen0ar ;our-&-)-$-+@ &!!

Caen0ar ;ours

$# E:ui2ment 'rea(0own

+# Pro*ess 'rea(0own

,# Start-Sto2 Rate Loss Per3orman*e E33i*ien*y

> ? A*tua Pro0u*tion@ &!!

B# Pro0u*tion Rate Loss Stan0ar0 Pro0u*tion

# .uaity De3e*t .uaity E33i*ien*y

> ?Pro0u*tion % .uaity Loss@ &!!

# Re2ro*essing Pro0u*tion

O4era Pant E33e*ti4eness > A4aia1iity Per3orm E33i*y  .uaity E33i*y

The Eight Ma=or Losses

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Feb '02 P N Patankar - CQP 7

Losses Cont0##

Pro0u*tion - Lost in Cases

Man2ower - Lost in CasesMateria an0 Energy- Lost in Cases

5hat are the Other Losses 6

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Feb '02 P N Patankar - CQP 8

Eer*ise

The chart shows the relationship between daily production in a month and losses.

Calculate the Overall Plant Effectiveness.

 

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Feb '02 P N Patankar - CQP

OPE Ca*uations

Calendar Time: 2 hrs ! "# days

Operatin$ Time: 2 hrs ! 2% days

∀  A4aia1iity > ?)+ )@F ?)+ $!@ &!! > "!

Production &olume:

'. ()## ! '* +('### ! ,* + (-## ! )* + (## ! '* '#/## t

2. ()## ! '* + ('### ! '2* + ()## ! '* '"### t

Total '#/## + '"### 2"/## t

Production 0ate 2"/##1 2% --) t 1 day

∀  Per3orman*e Rate > ,F &!!! &!! > #,

  '## t 0eect has been produced

∀  .uaity Rate > )$!! F )$"!! &!! > ""#B

∀  O4era Pant E33e*ti4eness > "! #, ""#B > "#$

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Feb '02 P N Patankar - CQP 10

Piars o3 TPM A*ti4ity

&# /o*use0 Im2ro4ement ?Ho1etsu Haien@

)# Panne0 Maintenan*e$# Autonomous Maintenan*e ?Jishu ;oen@

+# .uaity Maintenan*e ?;inshitsu ;oen@

,# Eary Management

B# E0u*ation an0 Training

# TPM in O33i*e

# Sa3ety8 ;eath an0 En4ironment

Target - P-.-C-D-S-M

 – Pro0u*ti4ity

 – .uaity

 – Cost

 – Dei4ery

 – Sa3ety

 – Moti4ation

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Feb '02 P N Patankar - CQP 11

Piars o3 TPM A*ti4ity

&# /o*use0 Im2ro4ement ?Ho1etsu Haien@

• O1=e*ti4e – Maimise O4era E33e*ti4eness o3 E:ui2ment8 Pro*esses8 an0

Pants

 – Through Eimination o3 Losses

 – In Cross- /un*tiona Teams

• Toos Use0

 – Dirty8 Di33i*ut8 Dangerous

 – Sim2i3y % Eiminate a Unne*essary8

Sur2us E:ui2ment

 – PM Anaysis

 – 5hy % 5hy Anaysis

 – /aiure Mo0e an0 E33e*ts Anaysis ?/MEA@ – Statisti*a Toos

 – Vaue Anaysis

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Feb '02 P N Patankar - CQP 12

Piars o3 TPM A*ti4ity - /o*use0 Im2ro4ement Cont0

• Ste2 'y Ste2 A22roa*h

 – See*t Pro1em

 – Un0erstan0 the Current Situation

 – E2ose an0 Eiminate

• A1normaities in E:ui2ment

• Restore Deterioration8 Corre*t Minor /aws

• Esta1ish 'asi* E:ui2ment Con0itions – Anayse Root-Causes

 – Pan Im2ro4ement

 – Im2ement

 – Che*( Resuts

 –Stan0ar0ise

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Feb '02 P N Patankar - CQP 13

Piars o3 TPM A*ti4ity - /o*use0 Im2ro4ement Cont0

• P M Anaysis ?Phenomenon % Me*hanism@

 – Stu0y at the $ A*tuas - – Esta1ish Physi*a Prin*i2a In4o4e0

 – In4estigate Measurement System

 – Esta1ish Root Cause

Man   Ma*hine

  E33e*t

Materia Metho0

 – Pan Counter Measure

 – Im2ement an0 /oow u2

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Feb '02 P N Patankar - CQP 14

Piars o3 TPM A*ti4ity

)# Autonomous Maintenan*e

Causes o3 E:ui2ment Deterioration

&# Dirt8 Dust8 Corrosion

)# Lu1ri*ation /aiure

$# Aignment8 Loose

I Run It8 Kou /i It

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Feb '02 P N Patankar - CQP 15

Autonomous Maintenan*e Cont0#

• Per3orm Initia Ceaning

 – Ceaning is Ins2e*tion – Ins2e*tion is Dis*o4ery o3 A1normaities

 – Eiminate A1normaities an0 Restore Origina Con0ition

• Eiminate Sour*e o3 Contamination

• Im2ro4e ;ar0 to Rea*h 2a*es

• Carryout , % S A*ti4ity

• Esta1ish %

 – Ins2e*tion Stan0ar0 an0 5hat is Norma

 – Lu1ri*ation System

 – Tightening System• De4eo2 One-Point Lessons an0 Train

• ;ow to Prioritise 6

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Feb '02 P N Patankar - CQP 16

Autonomous Maintenan*e Cont0#

E:ui2ment E4auation Criteria

Eement A Ran( ' Ran( C Ran(

S Sa3ety 9 En4ironment Dangerous Mo0erate Sa3e

. .uaity an0 Kie0 Serious Mo0erate Low

5 5or(ing )+ hr % &B hr Sometime

P Pro0u*tion Criti*aity ;igh Me0ium Low

' 'rea( 0owns /re:uent Sometime Rare

M Maintaina1iity Costy A4erage Easy

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Feb '02 P N Patankar - CQP 17

Autonomous Maintenan*e on Hette 1y O2erator 

 

Com2onent Ceaning Lu1ri*ation Ins2e*tion

/re:uen*y Metho0 /re:uen*y /re: Metho0

&# Agitator

 

&#& Motor 5ee(y Coth Ni Daiy Visua 3or noise8 4i1rations8

tem2erature8 oose nuts 9 1ots

 

&#) Gear 1o 5ee(y Coth 5ee(y Daiy Visua 3or noise8 4i1rations8

*o4er tem2erature8 Che*( oi e4e8oose nuts 9 1ots8 Oi ea(age

 

&#$ Cou2ing 5ee(y Coth an0 'rush Ni Daiy Visua 3or noise8 4i1rations8

tem2erature8oose nuts 9 1ots8

guar0 in 2a*e

 

&#+ Agitator 1a0es Keary Pro*e0ure & Ni 5ee(y with tor*h 3or any a1norma

wear8 1rea(age8 erosion

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Feb '02 P N Patankar - CQP 18

Autonomous Maintenan*e # ONE POINT LESSON

  3ept: 4arrel 5illin$ 6achine: 5or7lift ''# 6ade by: 8shish 9upta 2#.'#.#'.

'ATTERK

&  8cid 8cid level should always be between the 6in and 6a! mar7s. ;f the level is low< fill3istilled =ater with the help of 5unnel to brin$ the level up to the 6a! mar7.

2. 8fter fillin$ with distilled water< clean and wipe the battery with a clean cloth and screwonthe Plastic Cap 2. 6a7e sure that the vent hole in the cap is clean.

". Terminal – There are 2 terminals on the battery < one is + and the other is . Terminalshould always be 7ept clean. ;f you find a white or $reen coloured deposit on it< then openthe clamp with a spanner and clean it thorou$hly with wire brush and cloth. 8lso clean

the terminal similarly. 8pply white petroleum elly on clamp and terminal and ti$hten theclamp. 0emember to attach + clamp on the + terminal of the battery.. Clamp – 8lways 7eep it clean .). Char$in$ – 4attery should always be 7ept fully char$ed. Chec7 that the char$er on for7lift

is wor7in$ . Chec7 the char$e once in a wee7 with 6ar$e 6eter.,. ;f en$ine does not cran7 and start easily in the mornin$< this could be an indicator of >ow

4attery char$e.

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Feb '02 P N Patankar - CQP 1

$# .uaity Maintenan*e

• O1=e*ti4e %

 – Maintain .uaity

 – Constanty Im2ro4e .uaity

TOOLS -

• De3e*t Mo0e

• Root Cause Matri

• Pant 9 .uaity Matri• .uaity Maintenan*e Che*( List

 

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Feb '02 P N Patankar - CQP 20

Im2ementation o3 TPM

Ste2s Detais

A# Pre2aration

&# Announ*e to2 mgt 0e*ision tointro0u*e TPM

In3orm throughout the *om2anyarti*e in house magaine et*

)# Laun*h Training an0 *am2aignto intro0u*e TPM

Seminar8 Si0e 2resentation

$# Create organisation to 2romoteTPM Committee at e4ery e4e *oor0inate01y Centra sta33 

+# Esta1ish 1asi* 2oi*ies an0goas

Anayse eisting *on0itions8 setgoas8

,# /ormuate master 2an 3or TPM0e4eo2ment

Pre2are im2ementation 2ans 3or the3i4e 3oun0ationa a*ti4ities

'# Preiminary Im2ementation

B# ;o0 TPM (i*(-o33 In4ite *ustomers8 su22iers8asso*iates

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Feb '02 P N Patankar - CQP 21

TPM Im2ementation Cont0

Ste2s Detais

C# TPM Im2ementation

# Im2ro4e e33e*ti4eness o3 ea*h2ie*e o3 e:ui2ment

See*t mo0e e:ui2ment8 /orm 2ro=e*tteams

# De4eo2 AutonomousMaintenan*e 2rogramme

Promote se4en ste2s8 1ui0 0iagnosti*ss(is8 esta1ish wor(er *erti3i*ation2ro*e0ure

"# De4eo2 s*he0ue0maintenan*e 2rogramme 3ormaintenan*e 0e2ts

In*u0e 2erio0i* 9 2re0i*ti4e maint#8management o3 s2are 2arts8 toos80rawings an0 s*he0ues

&!# Con0u*t training to im2ro4eo2eration 9 maintenan*e s(is

Train ea0ers together 9 *as*a0e 0own

 

&&# De4eo2 eary e:ui2mentmanagement 2rogramme

Various te*hni:ues o3 earymanagement

D# Sta1iisation

&)# Per3e*t TPM im2ementation E4auate 3or PM 2rie8 set higher goas

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Feb '02 P N Patankar - CQP 22

Organisation /or Im2ro4ements

  To2 Management

  Managers

  Su2er4isors

  5or(ers

• Team Stru*ture 3or A Im2ro4ement Pro=e*ts

• Ea*h Manager must ha4e 2ro=e*ts 2ertaining to P . C D S M

5ithin the o4era o1=e*ti4es

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Feb '02 P N Patankar - CQP 23

Re*ognition an0 Rewar0 System

• 5hen Do I /ee Moti4ate0 6

 – -

 – -

 – -

 – -

• ;ow Cou0 I 1e Re*ognise0 6

 – -

 – -

 – -

• ;ow Cou0 I 1e Rewar0e0 6

 – -

 – -

 – -