tpm canteen

A Journey of Change initiated at

Guwahati Refinery

TPM in Industrial Canteen

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•Fortune 500 company

•Ranked 98th /only Indian company in the first

100 of fortune 500 .

•Largest Refiner of the country

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Care

Passion

Innovation

Trust

CORE VALUES

3

First Public Sector Refinery in India

Dedicated to the nation on 1st Jan, 1962

A 49 years old Refinery

Tucked away in the north east corner

GUWAHATI REFINERY ……….INDIANOIL

4

OFFICE TPM

IN

HR / CANTEEN5

Drives

The entire factory and work force

Holistic productivity improvement

system

TOTAL PRODUCTIVE MAINTENANCE( TPM )

6

TPM

Conference Hall

HR

Implementation

Knowledge and Implementation

Cycle

HR Facilitator

Guest House Canteen

HR Hall

CONCEPTUALIZATION AND IMPLEMENTATION OF OTPM

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Aims at improving Office

efficiency, productivity

and reduce Time losses in

Office processes and

procedures

OFFICE TPM

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OTPM follows a Five Pillar approach from conceptualization to implementation :

JH – Jishu Hozen

KK – Kobetsu Kaizen

E&T- Education &Training

PM - Planned Maintenance

SHE – Safety, Health and Environment

THE FIVE PILLAR APPROACH

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THE OFFICE OF 2007

Our Workplaces Looked Like This 10

Segregation of useful / wasteful records and documentation

Thoroughly cleaned tables, drawers and cabinets

Elimination of unnecessary documents

Indexation of all documents / files

Pre-fixed locations on tables / drawers / storage units

Creating a master record for all files & documents

Easy locating devices for the documents

APPROACH ADOPTED THROUGH 5 ‘S’

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SORTING…WEEDING

….. AND CLEARING

Initial 8 / 10 months

10 truckloads sorted out

EMPLOYEE ACCEPTANCE………..EMPLOYEE INVOLVEMENT

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Conceptualized By Employees

NEW OFFICE INFRASTRUCTURE - NEW AMBIENCE

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BEFORE AFTER

File cabinet in office hall Right thing at right place

FILING SYSTEMS WITH VISUAL MANAGEMENT

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FILE SYSTEM WITH COLOUR CODING AND INDEX

Visual Management

More than 5000 files in HR Dept

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FILE SEGREGATION AND FILE INDEX

File Index

Ownership

Indicator

Visual Management16

MASTER COLOR CODING AND LOCATION INDICATOR

Visual Management17

HR / SDU / 01 / HBA / 003 / 024

Page Code

Name of the Department

SDU Sl No.

Subject Area

File Number

Sheet Number

SDU/ Compactor

Document Retrieval Time Achieved : 30 – 35 seconds

INNOVATION : STANDARDIZED SHEET CODING

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M

I

N

U

T

E

S

YEAR

Better

PHASE WISE REDUCTION IN FILE RETRIEVAL TIME

Document retrieval < 35 seconds

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DESIGNATED PLACE FOR EVERYTHING

Office Table Stationary DrawerOwnership Labels20

Maintained On Rotation by HR Staff

DAILY MAINTENANCE CHECKLIST

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Employee seat Locations withEmployee Photographs

Workstation Wise EmployeeSeating and Job Areas

SEATING LAYOUT CHARTS

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ELIMINATION OF NVA

25 processes, 30% Saving achieved in Response

Time 23

List Index For Files In SDURack wise – Number wise

Office Equipment Ownership

HR HALL DISPLAY

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Response time Indicator

Efficiency Indicator

• Records incoming/outgoing HR applications

• Average Response time calculated and indicated every week

• HR efficiency evaluated and available on display

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TPM AT REFINERY

OVERVIEW OF TPM AT GUWAHATI REFINERY 26

PH - OMS

TPM AT GR REFINERY

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Why Canteen ???

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WHY CANTEEN ?

Scope for Improvement

Delightful

Services

2007

Parameters of Services

Establishment, Loans & Advances, Canteen Services, Guest House, Administration, Event Management, Furniture and Office MaintenancePost Retirement Services

Employee Satisfaction Index On HR Services

41 %

Others 40%

Canteen Services

60 %

Dissatisfaction Index on

Canteen services

59 %

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Systematically reduce Response Time

√ Develop /Turnaround Canteen into a Model Industrial Canteen

Strive for Employee Delight in all HR services

Identify and Remove Non Value Added Services in all areas

Computerize HR work processes for reducing processing time

HR Goals - 2008

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No tracking/planning

For Grocery

ProcurementIndividual Work

Style-No system

approach

Poor ambience in

offices / storeroom

Average Food QualityPoor Hygiene

And cleanliness

Improper Storage of

Materials/Food Stuff

Canteen Of

2007Improper waste

Disposal

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OUR CANTEEN HALL OF 2007

Dull, Ordinary, and non vibrant32

THE STORY BEFORE TPM…

No system for storing Grocery!

No means of tracking the Grocery levels!

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No means of food waste disposal!

THE STORY BEFORE TPM…

Customer Dissatisfaction 34

ENHANCE CUSTOMER

SATISFACTION

Organic Waste

Disposal

Automation for

Customer Delight

Systematic Documentation of Office Records

Introduce Grocery

Tracking Systems

Ownership Systems

For

Maintenance/Upkeep

OBJECTIVES

IdentifiedImprove

Ambience and Hygiene

Improve Food Quality

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Change…….Change...Change...Ideas

THE FOCUS OF ALL NEW EFFORTS

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A NEW VISION

Ordinary

Workmen

Canteen

Unique/Ambient

Industrial

Canteen

Of High

standards

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Autonomous Maintenance

Focused Improvement

Planned Maintenance

Quality Maintenance

Early Management

Safety, Health & Environment

Education & Training

OTPM

8 PILLAR APPROACH INITIATED

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AUTONOMOUS MAINTENANCE

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Kitchen Equipments

STEAM

Boiler

ROTI MAKER

OWC

Burners

POTATO

PEELER

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AUTONOMOUS MAINTENANCE

SOP for OWC & Checklist for maintaining all the equipments in Kitchen.

Maintenance of Automatic Rotimakerthrough Checklist

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FOCUSED IMPROVEMENT

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FOCUSED IMPROVEMENT FOR FOOD WASTE

DISPOSAL

OWC

Surrounding areas getting littered by canteen waste, foul smell, no daily

clearance by Civil Contractor, dependence on outside agencies

OPTIONS :

• Tie up with PWD

•Have own system

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RECYCLING ORGANIC FOOD WASTE

Collection of Organic Food waste from Canteen daily

Removal of steel, glass and plastic particles/items from the waste

Shredding the bigger hard items like bones, lemon pieces etc into the shredder

Grinding the remaining waste into the OWC along with saw dust and chemicals

Culturing the processed waste into manure through the pruning system in 10 days.

Using the manure in cultivation of plants in and around refinery.

The manure prepared from OWC is used in the refinery and township garden 45

RECYCLING ORGANIC FOOD WASTE

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KAIZEN FOR RECYCLING ORGANIC FOOD WASTE

FOCUSED IMPROVEMENT

• Old closed vessel

Storage for grocery

• No means to clean inside

• Materials get drawn

from top regularly

• No means to track

consumption levels

Earlier Storage Systems

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Focussed Improvement

Phase 1 Phase 2

Transition

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FOCUSED IMPROVEMENT

Pondering on challenging assignment posed by Japanese auditors

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Idea of new vessel with transparent strip / Bottom valve

Why Not POKA YOKE ?

(mistake Proofing)

FOCUSED IMPROVEMENT

50

Transparent Strip introduced for

Grain level visibility without

opening lid cover

Bottom Opener for Drawing out

Material – FIFO Concept

DESIGNED BY TPM CIRCLE EMPLOYEES

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FOCUSED IMPROVEMENT

FIFO System For Grocery

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PLANNED MAINTENANCE

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PLANNED MAINTENANCE

Daily Check listing for Maintaining, Grocery Room, Kitchen, Grocery Level, Main Hall

5454

MAINTENANCE OF AUTOMATIC ROTI MAKER (ARM)

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MAINTENANCE OF ORGANIC WASTE CONVERTER (OWC)

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REGULAR MAINTENANCE THROUGH CHECKLISTING

Regular Monitoring of Checklist by Senior Officer. 57

QUALITY MAINTENANCE

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QM – Display of Brands Of Raw Materials Used

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QUALITY MAINTENANCE

Weekly inspection by Nutritionists

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QUALITY MAINTENANCE

Surprise Inspection by Canteen Committee

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SERVICE QUALITY MAINTENANCE

Introduction of a Suggestion Book

Collect feedback on Food, Ambience and Hygiene Conditions

daily

Review the Suggestion at the end of each day

Take action on immediate problems

Take up critical suggestion in weekly meeting

Implement improvement in the service

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EARLY MANAGEMENT

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EARLY MANAGEMENT

Learning From Experience

To Learn from Guwahati experiences , HR Heads Meet of all IOCL Refineries held in September’10

GR Canteen benchmarked for Display, Storage and SHE systems

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EARLY MANAGEMENT

HR Heads of Other Refineries having on spot experience

Of change

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SAFETY, HEALTH & ENVIRONMENT

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SAFETY

Safety gloves, shoes, mask and apronDisinfecting and Pest Control

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SAFETY

Cooks working in Kitchen and a boy serving food to guests68

INPUTS ON HEALTH/HYGIENE

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HEALTH

BMI Measurement in Canteen Hall 70

Pictorial Charts on Health/Nutrition in Canteen Hall 7171

ELECTRONIC SCROLLER ON HEALTH/

NUTRITION TIPS

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SHE : CARE FOR ENVIRONMENT

Treats Organic Waste (Food Left

Over, Raw Vegetables etc.) 60-70

KG of waste per day into Manure

Eco friendly treatment

Manure is used in Public Flower

Parks and Nurseries in and around

Refinery campus.

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EDUCATION & TRAINING

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EDUCATION AND TRAINING

TYPES OF TRAINING

In house Training

Sponsored Training outside Refinery

•TRAINING PROGRAMMES

Soft Skills training by Hotel Management faculty twice in a year with practical classes

Safety training by F&S dept every 6 months.

Training by Nutritionists on preparing healthy balanced food.

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SOFT SKILLS INPUTS BY HOSPITALITY EXPERTS

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ONE POINT LESSON

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OFFICE TPM

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OTPM - RE-ORDER LEVEL IN GROCERY MANAGEMENT

Material Re-Order Level is defined and indicated in each storage vessel/rack for proper tracking

Green Colour

Yellow Colour

Red Colour

SU

FF

ICIE

NT

ST

OC

K

RE

-OR

DE

R

LE

VE

L

CR

ITIC

AL

ST

OC

K

MATERIAL RE-ORDER LEVEL CHART

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Office and Storage

A place for everything and everything in its place

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Visuals

Planning & Scheduling Standardization

Color Code Identity Chart

For Using → Switches in

Canteen Hall

Color Codes For Lights , fans and Fittings

in Hall

82

Checklist for maintaining Plant Canteen

CHECKLISTING & OWNERSHIP

Grocery Room Ownership indicator

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OTPM : RE-ORDER LEVEL IN GROCERY MANAGEMENT

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OTPM : RE-ORDER LEVEL IN GROCERY MANAGEMENT

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OTPM : IMPROVED GROCERY MANAGEMENT

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ONLINE MEAL BOOKING SYSTEM

•Better Planning•Less Food Wastage

•Cost Monitoring

Intranet Card Reader

Electronic Kiosk

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Winning TPM awards by Canteen Team

A Routine Affair

Participation In TPM Competitions

The Winning Team

We Own And Proudly Maintain

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With a

Difference

An Industrial Canteen

WHAT DID WE ACHIEVE ?

90

CLEAN AND PLEASANT AMBIENCE

Turnaround ………Industrial Canteen 2011 91

A PLACE FOR ENJOYABLE MEALS FOR ALL

92

A CURIOUS PLACE FOR VISIT BY CHAIRMAN/VIPS/DIRECTORS

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REGULAR STREAM OF VIPS

94

REGULAR STREAM OF VIPS

JIPM Team Visit at Canteen in Jan 2010

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VIP VISITS

Our proud Team with JIPM Team including Prof Yoshio Tanaka San, Mr KinjiroNakano

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TURAROUND ON CANTEEN SERVICES

30%

70%

2007

Delighful Services

Scope for Improvement

75%

25%

2011

Delightful Services

Scope for Improvement

Satisfaction Index

97

Providing Hygienic, Quality Food in Ambient Environment

Consistently Strive and Innovate For

MISSION OF CANTEEN STAFF

98

Quality Of Services

assessed every Six

Months Areas For

Improvement

Displayed in Chart in

Hall

PERIODIC CUSTOMER FEEDBACK

99

They came, saw and Wrote

“Impressed by the cleanliness and orderliness of Canteen. Other organizations in the city must take lessons from them.”

- N. I. Laskar, Executive Editor, Eastern Chronicle

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They Continue to write…

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Proud To Compare

Refinery Industrial Canteen A Mc Donald’s Outlet

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Sustenance

And

More New Interventions

WAY FORWARD

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WAY FORWARD

Strive for Consistent ImprovementWin The TPM Sustenance award - 2012

Team Canteen

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