A TIMES OF INDIA SPECIAL REPORT By H.R.

Gupta

THE LATEST QUALITY MANTRA TOTAL PRODUCTIVE MAINTENANCE

(Courtesy : The Machinist)

n ancient times, the e

!i"e# a $a me % He &e!ie"e# in

s'(e nat' a! ()*e s an# 'se# t) *) shi( +)# *ith sta'nch $aith% One $ine m) nin,, (!ease# *ith his #e")ti)n, +)# a((ea e# an# as-e# the $a me t) see- an. &))n% The $a me t) see- an. &))n% The $a me as-e# +)# t) ma-e his hen !a. ,)!#en e,,s% /e it s) 'nti! .)' $ee# an# ca e $) the hen &.

.)' se!$ sai# +)# an# #isa((ea e#% The ()'!t . $a me &ecame ich "e . s))n% + ee# )"e t))- him% S))n he $)'n#, he &ecame !a0. an# c)'!# n)t atten# t) the hen% He hi e# (e)(!e t) #) the 1)& $) him% T 'e t) the &))n, the hen st)((e# !a.in, ,)!#en e,,s an# s))n #ie#%

The above tale is similar to our production facilities and equipment that exist in our industries. The attention we pay to goose laying golden eggs is dismal. A rough estimate shows that the Overall Equipment Effectiveness (O.E.E of plant and machinery in engineering industry is not more that !"# in India. O.E..E in Indian companies can be loosely divided as $%&'"# in an average industry( '"&"%# in well managed companies and )"# in world class companies. S'n#a am 2astene Limite#, a c)m(an. a(i#!. m)"in, t)*a #s &ec)min, *) !# c!ass, )(e ates at 345 O%E%E . *et us see how you can calculate the Overall Equipment Effectiveness of your equipment or the plant as a whole.

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A TIMES OF INDIA SPECIAL REPORT By H.R.Gupta

THE LATEST QUALITY MANTRA TOTAL PRODUCTIVE MAINTENANCE

(Courtesy : The Machinist)

TPM E6CELLENCE A7ARD

S'n#a am 2astene s Lt#%, a TVS + )'( )$ C)m(an., has &een a*a #e# the ( esti,i)'s TPM E8ce!!ence A*a # &. the 9a(anese Instit'te )$ P!ant Maintenance :9IPM;% The a*a # has &een ,i"en t) S2L a$te a i,) )'s a'#its )$ its (!ants &. a'#it) s $) m 9IPM an# it *as ( esente# t) M % S' esh < ishna, Chai man = Mana,in, Di ect) , )n Oct)&e >? th @ ABBC at $'ncti)n he!# in T)-.), 9a(an% The 9IPM a*a # is ec),niti)n that S2L has m)"e# s'&stantia!!. #)*n the )a# t)*a #s c eatin, a c) () ate s.stem that ma8imi0es the e$$icienc. )$ its ( )#'cti)n s.stem% The 9a(anese instit'teDs TPM ( ), amme is a ten .ea (ac-a,e that &asica!!. attem(ts t) achie"e an# maintain 0e ) #e$ects, 0e ) acci#ents an# 0e ) $ai!' es in the enti e !i$e c.c!e )$ a ( )#'cti)n s.stem% It is a((!ica&!e t) a!! a eas )$ an ) ,ani0ati)n inc!'#in, ( )#'cti)n, a#minist ati)n an# #esi,n an# #e"e!)(ment% S2L -ic-e# )$$ the TPM ( ), amme in A','st ABBE an# )"e the (ast th ee .ea s ha# ma#e c)nsi#e a&!e ( ), ess in si,ni$icant!. & in,in, #)*n the n'm&e )$ & ea-#)*nDs, acci#ents, 1)& chan,e time, c'st)me c)m(!aints an# e"en the a#minist ati)nDs #)c'ment et ie"a! time% I$ the c)m(an. n)* ,)es )n t) c)m(!ete the ten .ea ( ), amme it *i!! &e e!i,i&!e t) &e ce ti$ie# as a *) !# c!ass c)m(an. &. 9OPM
Assume that you have equipment + A and you have bought it to run on two , shift basis. This equipment will be available for utili-ation in a year only for ."% out of /%% shifts planned for wor0 after reducing absenteeism of operator , !%#( brea0down and maintenance wor0 , !%#( on 1obs available on the machine , "# (2unday( holidays( bandhs and other disturbances excluded .Out of ."% shifts available( considering )% minutes stoppage of equipment per shift for lunch( tea( coffee and persona time( startup and closing time allowances for operator( we loose 3" shifts per year. The machine is actually available for production only for '/" shifts. Therefore( the utili-ation efficiency of the machine is '/"4/%%5%./%3 (/%.3# . Though the machine is available for utili-ation for '/" shifts( the output per shift from this machine may not be equal to its rated capacity per shift. This happens due to several reasons. 6e are not able to use cutting speeds and
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A TIMES OF INDIA SPECIAL REPORT By H.R.Gupta

THE LATEST QUALITY MANTRA TOTAL PRODUCTIVE MAINTENANCE

(Courtesy : The Machinist)

feed as recommended by the machine tool manufacturer( we may have reduced parameters due to tool life or wor0piece accuracy requirements( the operator looses some time in searching for tools( 1igs and fixtures( setup time is longer than envisage etc. *et us say a part has a standard time of !%% hours. 7ue to all the above types of problems( it may actually ta0e !'% hours to produce this part. Therefore( the output efficiency of this equipment for '/" shifts( we receive output equivalent to output of $3% shifts ('/"x%.8/)

O"e a!! EF'i(ment E$$ecti"eness%

34%

18% 8% 8%

.#

4% 13% 11%

!. $. '. ..

2unday 4 9olidays , '.# :rea0down , 3# *unch( Tea 4 ;ofee , !!# <oor =uality *oss , .#

". /. 8. 3.

Absentism , 3# >o ?obs , .# Output Effiuciency *oss , !'# Actual Effective 6or0. , !3#

6e have yet to reach a stage of + @ight Airst Time B. Therefore( parts get re1ected during the stage of manufacturing as well as we some times salvage them through rewor0. A single machine may produce parts !%% per cent right first time but when this part goes to next operation to get re1ected( the wor0 done by the previous machine also goes waste. *et us say that on an average !%# of the wor0 done by a manufacturing shop is wasted in rewor0 and re1ections. Therefore( =uality Efficiency of the manufacturing plant would be %.)% ()%# . This means that though we produced output equivalent to $3% shifts( output equivalent to $"$./ shifts ($3x%.) was right first time and the balance time spent in rewor0 or re1ections. 6e spent in rewor0 or re1ections. 6e can now conclude by saying that the overall equipment is .$.!# ($"$./4/%% 5 %..$!# . If you consider the entire Indian engineering industry as a whole( overall utili-ation efficiency is not more than '"# (0eeping in view the underutili-ed equipment available in companies ( output efficiency not more than /%# and quality efficiency not more than 8%# resulting in Overall Equipment Effectiveness of !"#.

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A TIMES OF INDIA SPECIAL REPORT By H.R.Gupta

THE LATEST QUALITY MANTRA TOTAL PRODUCTIVE MAINTENANCE

(Courtesy : The Machinist)

Imagine if the O.E.E of your plant was greater than 3"#. ;ould you reduce your manufacturing process cost by more than "%# besides reducing throughput&time( increased inventory turns( higher inflow of absolute profits through increased volumes of production and higher levels of adherence to committed delivery schedules and thereby increased customer satisfactionC DesC IsnEt it a gold mine at homeC. The Latest Q'a!it. Mant a G + Total <roductive Faintenance B (T<F is all about improving the Overall Equipment Effectiveness (O.E.E of your plant. Gnfortunately( a magic wand is not available in our hands that can change the situation in a 1iffy. 6e have to inculcate faith and devotion to the religion of T<F in achieving salvation from competitive pressures and move towards wor0 class manufacturing. Dou will have to practice and chant the mantra of O.E.E all the time. As you 0eep on crossing milestones on you 1ourney towards T<F( you will 0eep receiving rewards and benefits in the bottom line of the company. :ut how to beginC As n) sa!"ati)n is ()ssi&!e *ith)'t the he!( )$ a +URU , .)' *i!! nee# a Teache *h) can ,'i#e .)' )n .)' (ath )$ ( acticin, TPM% 9a(anese Instit'te )$ P!ant Maintenance :9IPM; introduced the concept of TOTAL PRODUCTIVE MAINTENANCE to the 6orld in early !)8%Es. T<F in In#ia is at a sta,e )$ in$anc.% Vi- am Cements( a #i"isi)n )$ + asim In#'st ies( *as the $i st C)m(an. in In#ia t) ecei"e /est TPM P!ant A*a # in ABBE an# S'n#a am 2astene s Limite#, the sec)n# c)m(an. in ABBC% :oth these companies have succeeded only because Fr. Aditya Hi0ram :irla and Fr. 2uresh Irishna chairman of respective companies spearheaded the program. Therefore( the chairman or the Fanaging 7irector will have to ma0e a public pronouncement of their + 2an0alp B (determination having adopted T<F as a religion for manufacturing management and personally lead this movement. :ut what does T<F meanC The ( ima . )&1ecti"e )$ TPM a e t)H C eate a mana,ement s.stem that (!ans, im(!ements, m)nit) s an# c)ntin')'s!. im( )"es :O%E%E; )$ the man'$act' in, $aci!itit.% C eate ( )cesses that can ass' e 0e ) #e$ects, 0e ) & ea-#)*ns, 0e ) acci#ents an# 0e ) !)sses% C eate t)ta! em(!).ee in")!"ement in achie"in, O%E%E% an# e!iminatin, *aste th )',h sma!! , )'( acti"ities% The implementation of T<F promoted by ?apanesse Institute of <lant Faintenance (?I<F is classified in eight categories.

O"e a!! EF'i(ment E$$ecti"eness%

OEE I Act'a! O(e atin, Time 6 Act'a! SPH ( )#'ce#
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A TIMES OF INDIA SPECIAL REPORT By H.R.Gupta

THE LATEST QUALITY MANTRA TOTAL PRODUCTIVE MAINTENANCE

(Courtesy : The Machinist)

A"ai!a&!e Time 6 +))# P )#'cti)n T)ta! P )#'cti)n

The) etica! SPH A"!%

SPH I Stan#a # P )#'cti)n H)' s%

In#i"i#'a! Im( )"ementsHJ E"e . em(!).ee in the c)m(an. m'st &e ma#e a*a e )$ the a eas the c)nt i&'te t) !)sses an# h)* he can he!( e!iminate #e$ects $ )m his )*n *) - an# c)nt i&'te t) e#'cti)n )$ !)sses c)m(an. *i#e% This acti"it. (e tains t) t ainin, (e)(!e in im(!ementin,, s(ecia!!. the sta$$ an# sh)( s'(e "is) s )n h)* t) a## ess e!iminati)n )$ A4 a eas )$ ma1) !)sses that e8ist in an. man'$act' in, set G '(% An# a!s) ens' e 0e ) !)ss #'e t) eF'i(ment $ai!' e an# ( )#'ct #e$ect% PLANNED MAINTENANCEH J Sta$$, s'(e "is) s an# maintenance team nee# t) &e t aine# t) im( )"e F'a!it. )$ maintenance *) - )n the eF'i(ment that *i!! ens' e 0e ) & ea-#)*ns% This inc!'#e# #ata c)!!ecti)n, ana!.sis an# time!. c)!!ecti)n acti)ns an# time!. c)!!ecti)n acti)ns )$ ( e"enti)n )$ ec' ence% Ve . )$ten shi$t a an,ements a e ma#e t) -ee( the eF'i(ment '( #'e t) n)nJa"ai!a&i!it. )$ s(a e (a ts ) ina&i!it. t) #ia,n)se a (a tic'!a ( )&!em at that time% S'ch acti"ities c eate a (e manent #isa&i!it. in eF'i(ment an# se i)'s!. a$$ect the ca(a&i!it. )$ the eF'i(ment inc!'#in, t)ta! !i$e c.c!e )$ the asset% The (!anne# maintenance acti"it. sh)'!# ens' e time!. attenti)n t) a!! t.(es )$ e(ai s that *i!! a")i# ma1) & ea-#)*ns%

Mate ia! 2!)* S.stemHJ In an. man'$act' in, sh)(, !)catin, )$ t))!s, 1i,s an# $i8t' es an# )the han#t))!s ta-e s)me time )n!. &eca'se these ha"e n)t &een st) e# s.stematica!!. an# (e)(!e ha"e t) sea ch $) these t))!s% Q'ite )$ten, the eF'i e# t))! is n)t in st)c- *hen eF'i e#% /a!ancin, )$ !)a# )n machines is .et an)the ma1) iss'e% S)me machines a e )"e !)a#e# an# s)me *aitin, $) mate ia!% A!! this !ea#s t) !)ss t) ( )#'cti"e h)' s )$ the machine t))!% P ima . )&1ecti"e )$ mate ia! $!)* mana,ement sh)'!# &e t) ens' e 0e ) *aitin, time $) a!! t.(es )$ in('t mate ia! an# sh) test th )',h('t time
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A TIMES OF INDIA SPECIAL REPORT By H.R.Gupta

THE LATEST QUALITY MANTRA TOTAL PRODUCTIVE MAINTENANCE

(Courtesy : The Machinist)

th )',h the chain )$ ( )cess% The e$) e, im(!ementin, acti"ities that can !ea# t) sh) tenin, the t ia! (e i)# $) ne* ( )#'cts ena&!in, hi,he a"ai!a&i!it. )$ eF'i(ment $) e,'!a ( )#'cti)n% In case )$ ne* eF'i(ment sh) ten #e"e!)(ment, #esi,n, an# man'$act' in, (e i)#s% Esta&!ish sh) test th )',h('t time )$ ( )#'cts% Im( )"e ( )cesses that can ass' e nea !. 0e ) sh) t sta t '( time )$ ne* eF'i(ment )n a i"a!% E#'cati)n an# T ainin,H J E#'cati)n an# T ainin, is the ( ime acti"it. t) ma-e the ( )cess s'ccee#% This inc!'#es t ainin, $) e"e . )ne in the c)m(an. sta tin, $ )m the ti( t) the !ast em(!).ee% S-i!! t ainin, $) )(e at) s an# maintenance team sta tin, $ )m &asic an# c)ntin')'s!. ,) )n t) im( )"e thei c) e c)m(etence in the tas- the. a e e8(ecte# t) (e $) m% A't)n)m)'s MaintenanceHJ The &asic ( emise )$ TPM !ies in the $act the machine )(e at) sh)'!# maintain the machine himse!$% It is s)methin, !i-e a ca # i"e% He is ta',ht the &asic s-i!! t) e(ai min) ( )&!ems in the ca s) that he is es()nsi&!e $) 0e ) & ea-#)*n )$ the ca )n the )a#% T) achie"e this ,)a!, he c!eans the ca e"e . #a., chec-s c itica! eF'i ements #ai!. an# see-s the he!( )$ e8te na! maintenance team at e(ai *) -sh)(s i$ he $in#s ma1) #e$ect% The e$) e the machine )(e at) s nee# t) &e t aine# t) 'n#e stan# thei machines *e!! an# he!# es()nsi&!e )"e a (e i)# )$ time $) thei machine '(time% The )!e )$ )(e at) , the e$) e, *)'!# inc!'#e c!eanin, the machine, #ai!. chec-J'( an# ana!.sisK ca .)'t sim(!e stan#a #i0e# maintenance *) -, a an,in, maintenance th )',h s(ecia!ists maintenance teamJ (e i)#ica!!. an# the e&. im( )"in, t)ta! !i$e c.c!e )$ the asset% The )!e )$ eF'i(ment &'i!#e nee#s t) &e e#e$ine# in te ms )$ his es()nsi&i!it. t)*a #s ma-in, his eF'i(ment $it $) TPM a((!icati)n the e&. ens' in, hi,h mean time &et*een $ai!' es :MT/2; an# sh) t mean time t) e(ai :MTTR;% Q'a!it. MaintenanceHJ Em(!).ees sh)'!# aim at Ri,ht 2i st Time the e&. Le ) G De$ect P )#'cti)n% T) achie"e this, it is necessa . that the sta$$ ec) #s act'a! #e$ects acc) #in, t) c)n$i me# stan#a #s an# ana!.ses the #ata t) e!ate #e$ects t) eF'i(ment ) ( )cess stan#a #s% C) ecti)n acti)ns sh)'!# &e im(!emente# th )',h <AILEN C )ss 2'ncti)na! Team, QC Ci c!e ) sma!! , )'( acti"ities% A#minist ati)n HJ
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A TIMES OF INDIA SPECIAL REPORT By H.R.Gupta

THE LATEST QUALITY MANTRA TOTAL PRODUCTIVE MAINTENANCE

(Courtesy : The Machinist)

Man'$act' in, e8ce!!ence #i ect!. #e(en#s )n the )(e ati)na! e8ce!!ence )$ s'(() tin, #e(a tments G (!annin,, (' chasin,, 'ti!ities etc% Sta$$ $ )m these #e(a tments sh)'!# &e t aine# t) s'(() t ( )#'cti)n #e(a tments *ith , eat s(ee#, acc' ac. an# c)mm)n (' ()se% Sa$et., Sanitati)n an# En"i )nmentHJ The *) - en"i )nment sh)'!# &e $ ee $ )m is- )$ acci#ents% The e sh)'!# &e a#eF'ate s.stems in (!ace t) ana!.0e# an# maintain 0e ) acci#ent !e"e!s% C eat a hea!th. an# c!ean *) -in, site $) the em(!).ees% The <e. t) s'ccessH Em(!).ees a e the $)'n#ati)n )$ TPM ( ), am% The. sh)'!# c!ea !. 'n#e stan# thei chan,in, )!e% It is the es()nsi&i!it. )$ the t)( mana,ement t) c eate a#eF'ate !e"e!s )$ m)ti"ati)n am)n,st (e)(!e t) ( )acti"e!. ass'me )*ne shi( )$ the tas-% S'n#a am 2aste ne Limite# *h) ha"e s'ccee#e# #i# n)t ha"e a sin,!e inci#ence )$ *) - st)((a,e ) a sin,!e !iti,ati)n *ith em(!).ee 'ni)n in the (ast M> .ea s% The e$) e the ( ime )!e )$ t)( mana,ement *)'!# &e t) c eate an attit'#ina! chan,e am)n,st (e)(!e t) acce(t the tenets )$ TPM% The )&"i)'s!. *)'!# eF'i e a (a a#i,m shi$t in the min#s )$ t)( mana,ement t)*a #s em(!).ees an# thei t a#e 'ni)n acti"ities%

7hat can .)' achie"e th )',h TPMN Y)' can inc ease e$$ecti"e 'ti!i0ati)n )$ eF'i(ment '(t) CE5 )"e a (e i)# )$ th ee t) $i"e .ea s the e&. e#'cin, the eF'i ement )$ a##iti)na! es)' ces $) inc ease# ( )#'cti)n an# e#'cin, man'$act' in, c)sts )$ the ( )#'ct% Y)' *i!! & in, machine & ea-#*)n t) 0e ) &esi#es e#'ce# maintenance c)sts% Y)' *i!! inc ease in"ent) . t' ns th )',h s(ee#ie mate ia! $!)* an# achie"e 0e ) acci#ents% CON2EDERATION O2 INDIAN INDUSTRY HAS 9OINED HANDS 7ITH 9APANESE INSTITUE O2 PALNT MAINTENANCE :9IPM; AND STARTED A TPM CLU/ TO PORMOTE PROI2IERATION O2 TPM AMON+ST THEIR MEM/ERSHIP% THE PHILOSOPHY O2 TPM IS MORE IMPORTANT THAN ITS NAME% 7HAT IS A MUST IS THIS APPLICATION O2 ITS PHILOSOPHIES COMPANY 7IDE TO ACHIEVE A COMPETITIVE ADVANTA+E%

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A TIMES OF INDIA SPECIAL REPORT By H.R.Gupta

THE LATEST QUALITY MANTRA TOTAL PRODUCTIVE MAINTENANCE

(Courtesy : The Machinist)

OOOOOOOOOOOOOOOOOOOOOOOOO6 OOOOOOOOOOOOOOOOOOOOOOOOOO

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