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

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: 1.After eliminating the need for replacing 1,152 gaskets, 3,744 hours of productive machine time was reclaimed 2.Eliminating oil-seal replacements led to reclaiming 1,536 hours 3.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

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)

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

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) T ( ) R = N - Q x 100 R= Rate of Quality Q = Non- conformities N = Processed amount (quantity) N ( )

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

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

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

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

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