improving overall efficiency of the cutting machines by impletation of pillars of tpm

8/9/2019 IMPROVING OVERALL EFFICIENCY OF THE CUTTING MACHINES BY IMPLETATION OF PILLARS OF TPM

1/29

MPROVING OVERALLEFFICIENCYF THE CUTTING MACHINES BY

MPLEMENTATION OF PILLARS.F TPM


2/29

MPROVING OVERALL EFFICIENCY OF THEUTTING MACHINES BY IMPLEMENTATION OF

ILLARS OF TPM

PREPARED BY

Name of the studentsq Yashraj.V.Rane.q Harshad.V.Suryawanshi.q

Kalpesh.D.Khochare.q Amol.P.Shetke.q Dhiraj.B.Waghmare.


3/29

Pillars of TPM


4/29

PILLAR 1 - JISHU HOZEN (Autonomous maintenance):

This pillar is geared towards developing operators to be able to take care of small maintenancetasks, thus freeing up the skilled maintenance people to spend time on more value added activityand technical repairs. The operators are responsible for upkeep of their equipment to prevent itfrom deteriorating.

PILLAR 2 KOBETSU KAIZEN:

"Kai" means change, and "Zen" means good (for the better). Basically kaizen is for smallimprovements, but carried out on a continual basis and involve all people in the organization.Kaizen is opposite to big spectacular innovations. Kaizen requires no or little investment. Theprinciple behind is that "a very large number of small improvements are move effective in anorganizational environment than a few improvements of large value. This pillar is aimed atreducing losses in the workplace that affect our efficiencies. By using a detailed and thoroughprocedure we eliminate losses in a systematic method using various Kaizen tools. These activitiesare not limited to production areas and can be implemented in administrative areas as well.

TPM Pillars ToImplement


5/29

Why Kobetsu Kiazen?

1. Easy to implement.2. It can be more cost effective compared to other

three processes.3. Everyone is involved during KK activity i.e. frommanager to shop floor worker

So that every operator gets the feel of experiment4. More operators friendly.

5. It can be done with less cost.


6/29

Why Jishu Hozen?

1.Easy to implement.

2.Uninterrupted operation of equipments.3.Flexible operators to operate and maintain other

equipments.4.Eliminating the defects at source through active

employee participation.


7/29

Behringer Band SawCutting M/C Losses

SR.NO. ACTIVITY TIME in min %

1. Setting if JOB 115 19.79

2. Measurement 83 14.28

3. Operator nonavailability

35 4.30

4. Crane waiting time 15 2.58

5. M/C down time 313 53.87

6. Tool changing time 30 5.16

TOTAL 581 100


8/29

Behringer Band SawCutting M/C Losses


9/29

Three Major Lossesin Behringer:-

1.

M/C Down Time.

Setting Time.

Measurement.


10/29

1. M/C Down Time

REASON

Maintenance

SOLUTION

Preventive Maintenance of M/C to be done ontime to avoid maintenance while M/C is inproduction.


11/29

2.Setting time

REASON Fatigue to Operator in Setting the Job.

SOLUTION Sensors are to be employed on machine for

measurement purpose.


12/29

3. Measurement

REASON Presently measurement is done manually by

operator.

New measurement type equipment must beprocured to minimize measurement time.

SOLUTION Sensors (stops)assembly has to be done near

to the machine blade so measurement


13/29

CNC Suag Cutting M/CLosses

SR.NO. ACTIVITY TIME inmin

%

1. Scheduled/Planned Stoppages 698 49.75

2. Setting Time 17 1.223. Start-up Losses[mock-up] 288 20.52

4. Minor Stoppage[Time Loss] 20 1.42

5. Non Availability of Material 340 24.24

6. Non Availability of Operator 40 2.85

TOTAL 1403 100


14/29

CNC Suag Cutting M/CLosses


15/29

Three Major Losses inCNC Suag:-

Scheduled/Planned Stoppages.Non Availability of Material.Start up Loss[mock-up].


16/29

Scheduled/PlannedStoppages REASON Loading Time Of Plate Is Too High.Time consumed for Setting the Job Plate.

SOLUTIONS Loading Time Should Be Minimized By OfflineSetting Of Plate.

Special fixture to be Designed for Quick Setting ofJob Plate.


17/29

on va a y o a er a

REASON Improper & Unplanned Stacking of Plates.

SOLUTIONS

Proper stacking of plates as per priority.Proper proactive planning to feed the m/c

as per plan.


18/29

Start up Loss[mock-up]

REASON No cleaning before Operator reports the

machine. Major time consumed in Test Run.

SOLUTIONS Special Cleaning staff to be provided for

cleaning of the m/c before operatorreports on the m/c during each shift.

Special Fixture to be made to avoid Test Run.

es gn pro a e so on


19/29

es gn pro a e so u onfor Behringer Band Saw

Cutting M/C


20/29

Actual implementationof scale

es gn pro a e so u on


21/29

es gn pro a e so u onfor CNC (Suag) Saw

Cutting M/C

c ua os on ng


22/29

c ua os on ngPlate For Reducing time

For Transportation

RE ULT BEF RE


23/29

RE ULT BEF REIMPLEMENTATION FOR BEHRINGER

BANDSAW CUTTING MACHINE.ATE OF PERFORMANCE EASUREMENT TIME/ /4 9 2009 20

/ /11 9 2010 30

RESULTS AFTER IMPLEMENTATION


24/29

RESULTS AFTER IMPLEMENTATIONFOR BEHRINGER BANDSAWCUTTING MACHINE.

ATE OF PERFORMANCE EASUREMENT TIME/ /22 04 2010 15

/ /23 04 2010 24

RESULTS BEFORE


25/29

RESULTS BEFOREIMPLEMENTATION FOR CNC GASCUTTING MACHINE - SUAG.

ATE OF PERFORMANCE VAILABILITY OF MATERIAL/ /11 9 2009 30

/ /25 09 2009 20

RESULTS AFTER IMPLEMENTATION


26/29

RESULTS AFTER IMPLEMENTATIONFOR CNC GAS CUTTING MACHINE -SUAG.

ATE OF PERFORMANCE VAILABILITY OF MATERIAL/ /22 04 2010 12

/ /23 04 2010 15


27/29

CONCLUSION

O. E. E. IMPROVED FOR BEHRINGERBANDSAW CUTTING MACHINE:-

DATE - / /efore 04 09 2009- / /fter 22 04 2010 - / /efore 11 9 2009- / /fter 23 04 2010

BEFORE O.E.E. .90 34 .48 86

AFTER O.E.E. .92 30 .60 87

. . .FROM ABOVE RESULTS IT CAN BE SEEN THAT O E E HAS BEEN IMPROVED BY% % .ALMOST 3 TO 15 AFTER THE IMPLEMENTATION OF TPM


28/29

CONCLUSION

O. E. E. IMPROVED FOR CNC GASCUTTING MACHINE CUTTINGMACHINE - SUAG:-DATE - / /efore 11 09 2009

- / /fter 22 04 2010 - / /efore 25 9 2009- / /fter 23 04 2010BEFORE O.E.E. .84 1 .78 3

AFTER O.E.E. .91 3 83

. . .FROM ABOVE RESULTS IT CAN BE SEEN THAT O E E HAS BEEN IMPROVED BY% % .ALMOST 3 TO 7 AFTER THE IMPLEMENTATION OF TPM


29/29

.HANK YOU.HANK YOU

improving overall efficiency of the cutting machines by impletation of pillars of tpm

Documents