Total Productive Maintenance (TPM) in Process Industry - ADDVALUE - Nilesh Arora

1. “TPM – Process Industry” by Best Performing Consulting Organization AddingValueInTotality!!

2. PROCESS INDUSTRY MEANS?? Those industries where primary processes are either continuous , or occur on a batch of materials that is indistinguishable e.g. Food processing ,cement industry, steel industry etc..

3. WHY TPM IN PROCESS INDUSTRY ? In Process Industry • The whole structure is based on machineries mainly. • The best way to earn profit is effective utilization of machineries which can be done by maintaining machines in good condition “ TPM is the solution of all problems”

4. Let’s go thru the case study of Grinding Unit , Kalol

5. WHY TPM @JKLC, KALOL ??? “To Make Kalol Grinding Unit The Best Grinding Unit Among All Cement Companies”

6. MILE STONES OF JKLC FOR TPM CERTIFICATION Zone division and cross functional teams prepared June-2013 Team Building Workshop Arranged Sep. 2013 Kicked off TPM with consultant Aprill-2013 Rigorous TPM execution started- Oct. 2013 Second Internal Audit November– 2014 First Internal Audit January-2014 Cleared Audit of TPM Level-1 December -2014

8. WHAT IS TPM?? • To become a world class organization, Organizations must achieve the following: - World class processes - World class people - World class machines • TPM is a tool which ensures that organization attain and sustain world class machines.

9. PROJECT INITIATION THRU LEAN-TPM Training

11. 8 PILLARS OF TPM

12. FOCUSED IMPROVEMENT • The pillar follows a structured set of steps aligned to the Plan, Do, Check, Act (PDCA) cycle, which can be implemented for improvement activities of any size or complexity in any organisation. • The pillar builds an understanding and analysis of the different loss types affecting an organisation. The pillar operates at a strategic level, identifying the criteria for project selection and TPM deployment that will deliver the business objectives.

13. AUTONOMOUS MAINTENANCE • This pillar is called Jishu Hozen (Autonomous Maintenance) AM itself is a 7 Step process • What is Autonomous ?? It means driven by self Self maintained INDEPENDENT OF OTHERS Maintenance dept----PM only

14. AUTONOMOUS MAINTENANCE • It is maintenance that is done autonomously ? (by the ‘self’ !!) • Now who is the ‘self’ ?? It is the operator(s) • A TPM pillar, which aims at ensuring that the BASIC CONDITION of the M/c / Equipment is maintained by the operators them self.

15. AUTONOMOUS MAINTENANCE • Cleaning - Dirt – poor or improper cleaning • OILING - No or inadequate oiling / lubrication • TIGHTENING - Neglecting early signals of vibration, mis-alignment, tightening bolts etc. • And reduce it and bring it back to its NORMAL life / or basic condition

16. JKLC First 10 months only & only COT • Rigorous cleaning is the only way to reduce break downs • Visual on machines lead to habitual cleaning to workers • TPM-Lean focuses on Visuals

17. AUTONOMOUS MAINTENANCE 7-Steps of Autonomous Maintenance • Initial cleaning • Counter measures • Provisional checklist • General inspection and tagging • Autonomous inspection • Standardization • Autonomous management

18. INITIAL CLEANING

19. COUNTER MEASURES • Improve the condition of the machine so that less time is spent in maintaining it. • Maintenance time must be targeted nearby 10 minutes /shift. If the maintenance time is high then identify why it takes more time?

21. PROVISIONAL CHECKLIST • Display-Who/What/ When/ How? • Fix day of the week, time & team to do the same tagging & untagging

23. OPL – One Point Lesson • When you find ABNORMAILITY in M/c – you tag it. • But.. when you find a ABNORMILITY in operators – you use a OPL.

24. One Point Lesson BIDCO Elianto Div Prepared by: ……….. Approved by ………. Prepared on: ……… Administered by ……. OPL Number: Type: Basic Knowledge: V-Belts Wrong Correct No vibration/oscillation of V belt indicates proper fit Vibrating belt indicates that belt is loose

25. AUTONOMOUS MAINTENANCE Finally • Make a AM Board • Put up 4 things on the board: • Look for list • Tag graph • Cleaning Schedule • OPL

26. One Point Lesson

27. PLANNED MAINTENANCE • Generally lead by maintenance team • The initial phase prioritises equipment and involves evaluating current maintenance performance and costs to set the focus for the pillar activity. • It can be done based on cost effectiveness suits the system (CBM/TBM)

28. TRAINING AND EDUCATION • The knowledge and skills required for carrying out each job are defined, in terms of both complexity of knowledge needed and the number of capable people required to support the business needs. • A current state analysis assesses the current levels against the established requirements and a training plan is developed to close any gaps.

29. EARLY MANAGEMENT • Early Equipment Management focuses on reduction of defect free process so equipment down time is minimal • Early Product Management aims to shorten development lead times, with teams working on simultaneous activities so that vertical start up can be achieved with zero quality loss

30. QUALITY MAINTENANCE • Quality Maintenance is implemented in two phases. • The first phase aims to eliminate quality issues by analysing the defects, so that optimum conditions can be defined that prevent defects occurring. • Then, the current state is investigated and improvements are implemented. • The second phase ensures that quality is sustained, by standardising the parameters and methods to achieve a zero defect system.

31. OFFICE TPM • Office TPM team implement office versions of Focussed Improvement and the Training and Education pillars to establish sustainable, performing processes. • To make office work smooth, office TPM is focused using 5S,LBM etc.

32. SAFETY, HEALTH AND ENVIRONMENT • SHE pillar activities aim to reactively eliminate the root causes of incidents that have occurred, to prevent Reoccurrence, and proactively reduce the risk of future potential incidents by targeting near misses and potential hazards.

33. 8 PILLARS OF TPM • J:\JKLC\TPM External Audit Level -1\8 pillar doc status.xls

34. TPM MEASURE: 1 OEE OEE= A factor * P factor * Q factor • Availability Factor = (Run time/ Net operating time)*100, • Calendar time = 30*24* 60 = 43200 min • Net operating time = Calendar time- (planned shutdown+ no schedule production + planned maintenance) • Run time = Schedule O.T. - Down time losses

35. TPM MEASURE: 1 OEE • Performance Factor = (Actual O.P/Total O.P)*100 • Quality Factor= (Good O.P/Actual O.P)*100

36. TPM MEASURE: 2 MTBF MTBF(Mean time between failure) = Total running time /Number of breakdowns TPM MEASURE: 3 MTTR MTTR(Mean time to repair) = Total down time /Number of breakdowns

37. TPM MEASURE 1: OEE

38. TPM MEASURE 2: MTBF

39. TPM MEASURE 3: MTTR

41. Trainings

42. Shop floor Clearing @5

43. New Bag Filter For Dust Control (Developed In-House) Kaizen Let Us Make Our Plant A Better Plant Every Moment.

44. Kaizen Fly Ash Unloading System One Truck Unloading Time - 14- 16 Minutes (Qty -17 Ton) Two Trucks Unloading Time - 18- 21 Minutes (Qty -34 Ton) Three Trucks Unloading Time - 40- 45 Minutes (Qty -51 Ton) Benefits: 1. Power Saving 2. Effective fleet utilization 3. Effective Plant Area Utilization ( Parking )

45. Kaizen

46. TEAM BUILDING WORKSHOP

47. Glimpse of JKLC Plant STORES Before After

48. Glimpse of JKLC Plant Cement Mill Area Before After

49. Glimpse of JKLC Plant Scrap Yard Area BeforeAfter

50. Glimpse of JKLC Plant Visuals at Shop floor and Lab