CAREER POINT UNIVERSITY, KOTAMAJOR ASSIGNMENT OF OPC

CASE STUDY OF TPM

PRESENTED BY :-ASHOK KUMAR SINGHUID – K10798BRANCH – MECHANICALCOURSE – B.TECHYEAR/SEM – 3RD /6TH

SUBMITTED TO :-MR. BHUPENDRA GAHLOTASSISTANT PROFESSORMECHANICAL DEPTT.

CONTENTS

• INTRODUCTION• PILLARS OF TPM• OBJECTIVES• BENEFITS• CASE STUDY

INTRODUCTION

• It is an innovative Japanese technique• It is the major part of the industry to improve the

effectiveness of productivity• It is applicable to every industry• Careful & intentionally working by employees in the

industry• Complete solution of all industry to increase the

productivity

PILLARS OF TPM

• Initial Flow Control Activity• Focused improvement • Autonomous Maintenance • Quality Maintenance • Planned Maintenance• Environment, Health and Safety• Admin TPM• Education and Training

OBJECTIVE OF TPM

• Involve people in all level of organisation• Achieve zero defect and zero accident• Increase production• Job satisfaction

BENEFITS OF TPM

• Increase OPE• Rectify customer complaints• Follow pollution control measures• Share knowledge and experience• Achieve goal by working as a team• High confidence level among employees

CASE STUDY[Gill Agricultural Implements Private Limited]

• It is a small scale industry• Located in Punjab• Main products are – multi crop thresher, tractor mounted

harvester, tractor mounted spray pump,self propelled harvester• We have done our case study on multi crop thresher assembly

line• Daily production is 10 machines/day• Work is divided for assembly of multi crop thresher on 12

stations

PROCESS FLOW DIAGRAM

SUGGESTION AND IMPLEMTATION OF TPM

• At time of Assembly of threshers there is no sequence of work and these cause to waste of time. After gives the suggestions Assembly of threshers working in line and this cause reduce the time of operation

• In these Industry workers has not well skilled in every work. Employee do only one type of work in Industry. This situation create problem at time of working. To solve this problem we create the skilled matrix generation method to improved skill of workers in Industry

• Before implementation TPM industry used shearing machine (manually operated), that consume lot of time and wastage of raw material. After suggestion industry has purchased plasma cutting CNC machine that has increase the quality and quantity of work and less man power required

• In the duration of lunch time (60 min) maintenance personnel must do preventive maintenance of the plant

Scrap loss before TPM Scrap loss after TPM

CONCLUSION

• We see that OEE value of this Industry is 60% approximately, this value is not good for industry and this cause to less profit .

• We found some type of problems and weakness of workers or industry at time of working. So we think that there is need of TPM Implementation in this Industry and after it we give some suggestion by the help of study TPM Pillars.

• Then we got the result, the working environment of this industry is improved and the OEE of Industry rise to 82%

• After the result clears that by the help of TPM, industry improved its OEE. IT directs help to increase productivity and profit of the industry.

CASE STUDY[M/S. SKYPET POLYMER]

• Produces plastic bottles and caps• Production takes place in two units which are 9 km

apart• In unit A , two injection moulding machine are present

and are used to make bottle caps.• In unit B, three blow moulding machines are present

where assembly with the caps , packed and dispatched are done

PROCESSES CARRIED OUT IN THE INDUSTRY

SUGGESTION AND IMPLEMENTATION OF TPM

• There is no sequence of work and these causes to Waste of time. After gives the suggestions Assembly of machines working in line and this cause reduce the time of operation.

• In the duration of lunch time (60 min) maintenance personnel must do preventive maintenance of the plant.

• Before implementation of TPM there is no proper working condition of workers. And after implementation TPM improved the working condition of workers by gives healthy food and purify ground water.

• At the initial phase of our study many employees consider it is an additional or burden but after implementation they feel that it is a win situation for industry and employees.

OEE CALCULATION BEFORE TPM OEE CALCULATION AFTER TPM

CONCLUSION

• By implementing the principles of lean manufacturing in the various processes, standardization was achieved as well as improved productivity in a few areas. The management was satisfied with the results the changes were able to produce.

• The following goals were accomplished:• The storage space in Unit A was standardized.• The productivity in Unit B improved after changing the layout. This was in the areas

of packing and material handling.• The inventory could be maintained better owing to a simple inventory management

system.• The OEE value was found to be only 75% approximately, now it has improved to

83%.• A better quality rate has been achieved as a result of implementing TPM.