New Page 3

Search  

Strategic Initiatives - Total Productive Maintenance

TBEM | Tinplate Promotion Council | Total Productive Maintenance
Total Operational Performance | 6 Sigma | Value Engineering | Quality Circles
HR Initiatives | IMS Certification | Knowledge Management | Benchmarking

In order to stay competitive, TCIL reworked its strategies on the highly influential market factors of quality, cost, delivery and most important customer sensitivity towards business transactions/services. The market survival challenge created the need to sweat assets by increasing the overall equipment efficiency (OEE), eliminate defects and build a safe & conducive working environment for self-motivated employees with ample opportunities of continuous improvement and learning.

This triggered the need for adopting TPM(Total Productive Maintenance) initiative, in TCIL.A Japanese initiative coordinated and supported worldwide by Japan Institute of plant maintenance was launched at TCIL in the year 2001-02.

TPM Award conferred upon TCIL by JIPM on 16th February 2006

JIPM consultant Mr. T.Watanabe at the inaugural ceremony
Motives of TPM
  1. Adoption of life cycle approach for improving the overall performance of production equipment.
    2.
  2. Improving productivity by highly motivated workers which is achieved by job enlargement.
    3.
  3. The use of voluntary small group activities for identifying the cause of failure, possible plant and equipment modifications.
Uniqueness of TPM The major difference between TPM and other concepts is that the operators are also made to involve in the maintenance process. The concept of "I (Production operators) Operate, You (Maintenance department) fix" is not followed.
TPM Objectives
  1. Achieve Zero Defects, Zero Breakdown and Zero accidents in all functional areas of the organization.
    2.
  2. Involve people in all levels of organization.
  3. Form different teams to reduce defects and Self Maintenance.
Direct benefits of TPM
  1. Increase productivity and OEE (Overall equipment efficiency) by 1.5 or 2 times.
    2.
  2. Rectify customer complaints.
    3.
  3. Reduce the manufacturing cost by 30%.
  4. Satisfy the customer’s needs by 100 % (Delivering the right quantity at the right time, in the required quality.)
    5.
  5. Reduce accidents.
    6.
  6. Follow pollution control measures.
Indirect benefits of TPM
  1. Higher confidence level among the employees.
    2.
  2. Keep the work place clean, neat and attractive.
    3.
  3. Favorable change in the attitude of the operators.
    4.
  4. Achieve goals by working as team.
    5.
  5. Horizontal deployment of a new concept in all areas of the organization.
    6.
  6. Share knowledge and experience.
    7.
  7. The workers get a feeling of owning the machine.

Top

Under the guidance of JIPM consultant Mr. T. Watanabe TCIL has carried its TPM journey over the last six years by successfully launching its eight pillars and measuring their effectiveness thru P(Productivity), Q(Quality), C(Cost), D(Delivery), S(Safety), M(Morale). During the initial phase of journey 100% of the employees underwent awareness training on TPM.

During the Phase 1 of the TPM journey, strong focus has been given in manufacturing sector, where Pillars like Jishu Hozen, Kobetsu Kaizen, Planned Maintenance, Quality Maintenance and Education & Training. have been launched in a big way to improve overall equipment effectiveness, Cost reduction, and cycle time reduction. This has been achieved through the efforts of various small group activities (JH circles) under JH Pillar, cross functional project teams of KK Pillar supported by planned Maintenance and Quality Maintenance Pillar. In order to enhance the knowledge and skill level of the employees, intensive training has been imparted through E & T Pillar to 100% of our employees..Under K K pillar all sixteen losses have been mapped and loss structure have been prepared and displayed in various units of CRM and ETP. During the second phase TPM was further extended to other functions like Finance, IT, Commercial services, Administration and HR under the umbrella of office TPM. IFC(Initial Flow Control) pillar was launched for the debottlenecking projects at CRM & ETP.

On 5th April 2005, TCIL cleared the TPM pre- audit by Mr. M. Sugiura and final TPM audit on 5th October 2005.The Tinplate Company of India Ltd. was conferred with the prestigious TPM Award on 16th February 2006 at Pacifico, Yokohama by Japan Institute of Plant Maintenance in a glittering ceremony.

TPM deployment has been started in the newly built Solution center to enhance its OEE.IFC Pillar which has been adjudged as one of the best practices in India by JIPM consultant Mr. T Watanabe is being successfully deployed for the expansion projects (ETL-2) after being institutionalized during the De-bottlenecking projects. Horizontal deployment of pillars like JH, KK, PM, QM have led to substantial improvements in OEE over the years and presently it is a world Benchmark at 92%. TCIL intends to continue its journey of TPM for continuos improvement become a role model TPM company in the years to come.

Top















New Page 7

Media | Achievements | Events | For our Suppliers |Customers' Section | Contact us | Sitemap | Home