business linkage centre (tpm) total ... -...
TRANSCRIPT
TRADE AND DEVELOPMENT BOARD COMMISSSION ON ENTERPRISE, BUSINESS FACILITATION AND
DEVELOPMENT
Expert Meeting on
"ENHANCING THE PARTICIPATION OF SMALL AND MEDIUM-SIZED ENTERPRISES IN GLOBAL VALUE CHAINS"
Geneva, 18-19 October 2007
PAPER SUBMITTED TO THE EXPERT MEETING*
BUSINESS LINKAGE CENTRE (TPM)
TOTAL PRODUCTIVE MAINTENANCE
by
Mr. Roberto Castillo UNILEVER, Vietnam
____________________ *The views expressed are those of the author and do not necessarily reflect the views of the UNCTAD
BUSINESS LINKAGE CENTRE
(TPM)TOTAL PRODUCTIVE MAINTENANCE
SMALL AND MEDIUM ENTERPRISES
Expert Meeting on
"ENHANCING THE PARTICIPATION OF SMALL AND MEDIUM-SIZED ENTERPRISES IN GLOBAL VALUE CHAINS"
Geneva, 19 October 2007
by
Roberto CastilloUnilever, Vietnam
“The views expressed are those of the author and do not necessarily reflect the views of the UNCTAD”
UNILEVER VIETNAM June 2007
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Unilever Vietnam has sponsored the Business Linkage Centre to work for the development of Small and Medium Enterprises.
These small and medium enterprises are the local third party manufacturers and suppliers of Unilever Vietnam.
The Business Linkage Centre operates under the auspices of the Royal Melbourne Institute of Technology (RMIT). They will have a link with the United Nations via UNCTAD and IPCN, Ministry of Planning and Investment (Bo KHDT) in order to be able to provide more funding for the development of the SME’s in Vietnam.
THE BUSINESS LINKAGE CENTRE
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HCMC
Can tho
LAOS Hai phong
BUSINESS LINKAGE CENTRE TPM PARTNERS-Manufacturers and Suppliers
HANOI
DngCAMBODIA
Lix Company (North)* - Detergent Powder
Net Company (North)*- Detergent Powder
Haso* - Toilet Soap, Household Care Liq.
Danang Chemical*-Detergent Powder,Fertilizer, Wooven Packaging Bags
* Vinachem Companies
Phu Quoc Island
Lix South*- DetergentPowder, Liquid Care
Net South*- Detergent Powder, Liquid Care
Huong Viet*- Fabric Conditioner Liquid
Danang Chemical* (South)-Det. Powders
Duy Tan Plastic Co-Plastic Bottles
LS Pack Company Ltd.-Laminated Tubes
Phuong Anh Food Processing Co-Tea
UNILEVER VIETNAM June 2007
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UNILEVER VIETNAM TPM PARTNERS
NORTH Third Party ManufacturersLix Detergent Joint Stock Company (North)Net Detegent Joint Stocks Company (North)Hanoi Soaps Joint Stocks Company
CENTRAL Third Party ManufacturersDanang Chemical Joint Stocks Company
SOUTH Third Party ManufacturersMicrobiological and Chemical Joint Stocks CompanyLix Detergent Joint stocks CompanyNet Detergent Joint Stocks CompanyDanang Chemical Joint Stock Company(South)Phuong Anh Food Processing Co
SuppliersDuytan Plastic CompanyLS Pack Company Limited
Six Third Party Companies & Two Suppliers
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THE LEVER VIETNAM THIRD PARTY
SME’s Volume – Annual Plan 2007
3,70511,96713,36014,680
24,253
56,087
85,79991,024102,058
116,325
156,957
178,800
284,600
1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007
86% of total production (62% in 2006).
284,600 tons planned production 3rd party.
39,500 tons planned for export(15%).
62 % of Net Proceeds of Sales.
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UNILEVER VIETNAM TPM PARTNERSSME’s Volume Actual 2006; Annual Plan 2007
86%62%% SME’s
100.0331,000289,200Company total
3.912,8009,800Other SME’s
3.913,00012,800Hanoi Soaps Co.
4.615,30017,700Lix Detergent Co.-South
8.227,00031,700Lix Detergent Company - North
10.033,30031,300Net Detergent Co.-South
11.738,60033,200Microbiological and Chemical Co.
14.247,000110,400Thu Duc/Cu Chi (In-House)
14.548,00036,000Net Detergent Company - North
29.096,0003,800Danang Chemical Co.
%AP 2007- tonAct. 2006- ton
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UNILEVER VIETNAM TPM PARTNERS2006 Workforce / No of Females – 40%
Danang Chemical Co. (Total Co - 204) - 78
Phuong Anh Food Processing Co. - 88
Hanoi Soaps Co - 104
Net Detergent Company – North - 165
LS Pack Company Limited* - 165
Lix Detergent Company – North - 210
Microbiological & Chemical Company* - 231
Net Detergent Company – South* - 360
Lix Detergent Company – South* - 690
Duytan Plastics Company* -1270
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Total Db %Con
Danang Chemical Company 150 2Lix Detergent Company 384 8Net Detergent Company 184 13Hanoi Soaps 395 25Duy Tan Plastic 432 33Huong Viet Company 17 100LS Pack Company Limited 96 100Phuong Anh Food Processing Co. 2 100
UNILEVER VIETNAM TPM PARTNERSSME’s Sales - %Unilever Contribution in 2006
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TOTAL PRODUCTIVE MAINTENANCE
Safety, Health and Environment Management
Quality Management
Focused Improvements (Kaizen)
Autonomous Maintenance
Planned Maintenance
Training and Development
TPM in Supply Chain
Early Equipment Management
8 TPM Pillars
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8 TPM PILLARS
BUSINESS LINKAGE CENTERTPM Training Modules-l
1. 5’S2. Kaizen3. Kaizen Tools4. Autonomous Maintenance l5. Autonomous Maintenance ll6. Autonomous Maintenance lll7. Safety, Environment & Hygiene
BUSINESS LINKAGE CENTRETPM Training Modules-ll
8. Quality Management
9. Presentation and Communication Skills
10. Boiler Operations and Safety
11. Planned Maintenance
12. Factory Visit
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BUSINESS LINKAGE CENTRE5’S
SeiriSeitonSeisoSeiketsuShitsuke
Sàng lọcSắp xếpSạch sẽSăn sócSẵn sàng
Sorting ArrangingCleaningStandardizingSelf Discipline
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BUSINESS LINKAGE CENTREFocused Improvement - Kaizen and Kaizen Tools
Kaizen ToolsFishbone/Ishikawa Diagram Why-Why Analysis 5 Why and 1 How Process Point Flow Chart Failure Mode & Effect Analysis
Pareto ChartsControl ChartsCheck ListMatrixScatter ChartPM Analysis
Kaizen- A process of improving factory operational performance which often results in cost savings
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OPERATOR BASIC MAINTENANCE COURSE
Operator Basic Maintenance Course lBolts and NutsLubrication
Operator Basic Maintenance Course llDrive TransmissionPneumatics
Operator Basic Maintenance Course lllElectricalInstrumentations
Target ParticipantsEngineering Mgr and Asst Eng’g ManagerShift leader/Supervisors and Group Leaders
Autonomous Maintenance – Operator Train the Trainor
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SAFETY TRAINING COURSE
Unilever Third Party Mandatory StandardsUnilever Safety OrganisationFirefigthingFirst AidePersonal Protective EquipmentGeneral safety AwarenessEnvironmental SafetyChemical SafetyCritical Equipment: forklift, boiler. Low and high voltage,
guarding
Risk assesssment: enzyme, confined space and working at heights
Safety Health and Env. - Safety Mgr Train the Trainor
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QUALITY ASSSURANCE COURSE
Quality ControlSampling Acceptable Quality LimitsAnalytical MethodsIn process control Packed product Finished product
Quality AssuranceEstablish and maintain conditions that does not lead to defects
Quality Management4m (man, machine, methods, materials) factors for machine operations
Quality Management - Direct Training
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PRESENTATION & COMMUNICATION SKILLS
CommunicationCommunication ModelForms of CommunicationCommunication ProblemsEffective CommunicationCommunication Styles
PresentationsFormatsVisual Aids, Charts, PictorialPosture, Body LanguageDo and Don’ts
Training and Development - Operator Train the Trainor
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BOILER OPERATOR COURSE
Boiler General and Steam Generation
Types of Boilers
Boiler Safety Equipment
Water Quality
Safety Checklist
Maintenance: Daily, Periodically, Yearly
Trouble shooting
Training and Development - Direct Operator Training
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PLANNED MAINTENANCE COURSE
Machine Classsification
Maintenance Strategy
Cleaning and Lubrication
Daily and Weekly Equipment Inspection
Master Equipment Schedule
Maintenance Procedure
Data Collection, Recording and Analysis
Spare Parts Control and Management
Planned Maintenance - Eng’g Manager Direct Training
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SME PROGRAMME
Mutual need resulting in a win-win situationUnilever grew very fast during its first ten years in Vietnam. It would have been impossible to cope with capacity demands. Had Unilever built capacity fast, the competitors would have lost their business.Hence we worked together with them in order to deliver the market demands.Unilever could have built the capacity required but we decided not to in VietnamAll low technology products are now made by our so-called friendly competitors (Laundry Product, Soaps)Unilever is concetrating in high technolgy products such as Oral care, Hair and Skin liquid products
Success Factors
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SME PROGRAMME
Use of the local languageAll of the SME’s we are dealing with do not have English capability ie the whole company including the General Director. We would have lost at least 50% of the knowledge had we used English during our training.Hence, all the trainings were being done in Vietnamese by Unilever trained Vietnamese people.We source the trainors from the company as required.We train the line managers and supervisors.
Success Factors
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SME PROGRAMME
Top level support from both partiesThe Unilever chairman fully suppports the training of the third party without any hesitation.The local companies, realising that importance of the training, and accepts all the training that Unilever delivers. They have actually no choice as they must deliver the quality that Unilever requires.There were serious doubts in our intentions in the beginning but all of these vanished after several years
Success Factors
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SME PROGRAMME
Persistence and subsistence in trainingWe did not train on the same subject once or twice. But we train on the subject deliberately as often as required. Sometimes we want to give-up but we realise that we have no alternative but to work with them.Sometimes they themselves ask for the training even we have already trained them before.
Success Factors
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SME PROGRAMME
Regular Audits and review in order to measure the progress
The companies are visited regularly, once every two monthsThey are rated on the progress of what they have learnedSometimes we encounter roadblocks ie no progress at all were seen. We implied that we would stop till a change will happen. But eventually they would deliver and we would start from there again.
Success Factors
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Success Factors
Visit to companies doing TPM
It is a standard practice for companies doing TPM to visit factories that have been doing TPM. This is to convince management of TPM’s beneficial effects.
Unilever Vietnam Cu Chi factoryIn Saigon, visits has been done to the Unilever VN Cu Chi Factory by LS Pack Company, Duy Tan Plastic Company, Lix Detergent Company and Huong Viet Company.
Hanoi Soaps FactoryNo visit has been scheduled in Hanoi yet but the HasoToilet Soaps Factory will be an ideal place to visit.
SME PROGRAMME
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Proactive ManagementPrivate & heavily equitised companies are a lot more interested in learning from the BLC. They are driven by the owners, and managing directors and even by the managers themselves In this case, the management are pro-active and hence they learn very fast.
e.g. Duy Tan; LSPack; and Cico
SME PROGRAMMEGeneral Issues
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SME PROGRAMME
Good DeputiesSome state companies show genuine interest because they are aware that the programme is good but does not seem to or do not know how to give it a high priority and delegates the job to the a deputy director whose success is dependent on the inclination of the deputy
e.g. Lix Co - South; Huong Viet, Lix North (Good Deputies)
General Issues
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SME PROGRAMME
Weak DeputiesSome state companies verbally pronounce that they are interested in the programme but:- It is clear from their behavior that they are not interested at all, or,- They refuse to understand the programme
They also leave it to their deputy who is also not interested. e.g. Net Co - South, Hanoi Soaps (Weak Deputy)
General Issues
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Testimonies of some of the SME’S
SME PROGRAMMESME Testimonies
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BUSINESS LINKAGE CENTRESmall and Medium Enterprises
End
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BUSINESS LINKAGE CENTREAutonomous Maintenance-By Operators
Autonomous Maintenance lIdentification of all kinds of defects and doing a Fugai chart
Autonomous Maintenance llRestoration of the machine to its original condition
Autonomous Maintenance lllPreliminary standardization of machine operating conditions
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OPERATOR BASIC MAINTENANCE COURSE l
Bolt & NutType and specificationMeasurement toolsMeasurement PracticeBolt and Nut ApplicationPractical Application
LubricationTypes of Lubricants
Lubrication Methods
Lubrication Tools
Lubrication Practice
Lubrication defects and inspection
Autonomous Maintenance l - Training Contents
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OPERATOR BASIC MAINTENANCE COURSE II
Drive TransmissionDrive transmission OverviewKey MechanismPin mechanismGear MechanismChain MechanismBelt Mechanism
PneumaticPneumatic Control SystemPneumatic ComponentsPneumatic CircuitsChecking and Inspection
Autonomous Maintenance ll - Training Contents
Coupling MechanismSlide MechanismBall BearingDrive Transmission DrawingInspection and Defect finding
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OPERATOR BASIC MAINTENANCE COURSE III
Electrical and Instrumentations
Theory and Basic CalculationsElectrical Distribution SystemHigh Voltage ElectricityTransformerLow Voltage ElectricityElectrical SafetyElectrical EquipmentsMotor - Inspection and MaintenanceControl InstrumentationsWiring - Checking and Maintenance
Autonomous Maintenance lll - Training Contents
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PLANNED MAINTENANCE
Sustainment (Prevent and fix failures)
Preventive MaintenanceRoutine MaintenanceTime based MaintenancePredictive Maintenance
Breakdown Maintenance
Maintenance Strategy
Improvement (Extend machine life, Reduce maintenance time,Design out maintenance)
Corrective Maintenance (Improved reliability)
Maintenance Prevention (Maintenance free design)
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TPM Familiarisation Training- 2 days.Training done separately by Company. Company Directors, vice directors and key managers (5-15 people). Venue at their site.
TPM Instructor’s Training- 5days.Training on key vice directors and managers who will lead TPM.8-10 people per company.
BUSINESS LINKAGE CENTRETPM Training