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SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 1 of 84
Sundram Fasteners Limited (SFL)Krishnapuram,
Madurai
Welcome
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 2 of 84
Success through loss elimination approach of Kobetsu Kaizen
Presented by:
S.M.Rajavikkiraman
Sundram Fasteners Ltd
Krishnapuram
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 3 of 84
TPM kick-off
Excellence Award
Consistency Award
Special Award
1995
1998
2004
2008
TPM implementation in SFL - Krishnapuram
Part 1
Part 2
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 4 of 84Courtesy:JIPM
Top Management
Planning Finance Personnel General Admin
Production Design & Development Materials Marketing
Plant 1 Plant 2 Plant 3
TPM Part 1 and Part 2
TPM Part 1: Main focus on factoryTPM Part 2: Company wide TPM including all functions
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 5 of 84
5S (Seiri – Seiton – Seiso – Seiketsu – Shitsuke)
Zero Accidents - Zero Defects - Zero Breakdowns – Zero Losses
Jish
u H
ozen
Plan
ned
Mai
nten
ance
Qua
lity
Mai
nten
ance
Edu
catio
n &
Tra
inin
g
Safe
ty, H
ealth
& E
nvir
onm
ent
Kob
etsu
Kai
zen
OT
PM -
Fact
ory
Initi
al C
ontr
ol –
P/E
8-pillar approach to TPM implementation in Part 1
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 6 of 84
Transition from Part 1 to Part 2
§ Addition of new pillars
§ OTPM - Purchase § OTPM - Marketing
§ Dividing the Initial Control P/E pillar as,
§ Initial control - Products§ Initial control – Equipments
§ Categorising the pillars as,
§ Internal focus pillars§ Customer focus pillars
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 7 of 84
5S (Seiri – Seiton – Seiso – Seiketsu – Shitsuke)
Hi Q – Lo C – Speed – Customer Delight
Zero Accidents - Zero Defects - Zero Breakdowns – Zero Losses
Jish
u H
ozen
Plan
ned
Mai
nten
ance
Qua
lity
Mai
nten
ance
Edu
catio
n &
Tra
inin
g
Safe
ty, H
ealth
& E
nvir
onm
ent
OT
PM –
Purc
hase
Initi
al C
ontr
ol–E
quip
men
ts
Kob
etsu
Kai
zen
OT
PM -
Fact
ory
OT
PM -
Mar
ketin
g
Initi
al C
ontr
ol–P
rodu
cts
InternalFocused
InternalFocused
CustomerFocused
CustomerFocused
11-pillar 2-tier approach to TPM implementation in Part 2
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 8 of 84
Step change
(Innovative/breakthrough activities)
Level of Performance
Period of time
Gradual improvement (Kaizen activities)
Gradual improvement (Kaizen activities)
Part 1 Part 2
Step Change in Part 2
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 9 of 84
Top 4 Pillars Focus area
OTPM-Marketing Strategies
IC-Products Technology
OTPM-Factory Systems
Kobetsu Kaizen (KK) Methodology
Focus areas for Step Change in Part 2
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 10 of 84
Top 4 Pillars Focus area
OTPM-Marketing Strategies
IC-Products Technology
OTPM-Factory Systems
Kobetsu Kaizen (KK) Methodology
Focus areas for Step Change
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 11 of 84
Success through loss elimination approach of Kobetsu Kaizen
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 12 of 84
Success through Kobetsu Kaizen approach
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 13 of 84
Objectives of KK pillar
q Improve OEE/OPE of equipments
§ Through reduction of time losses From 16 major losses Additional new losses
q Achieve total product cost reduction
§ Through reduction of resource losses From 16 major lossesAdditional new losses
§ VA/VE improvements
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 14 of 84
Objectives of KK pillar
q Improve OEE/OPE of equipments
§ Through reduction of time losses From 16 major losses Additional new losses
q Achieve total product cost reduction
§ Through reduction of resource losses From 16 major lossesAdditional new losses
§ VA/VE improvements
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 15 of 84
Methodology for total product cost reduction
Establish relationship between
1. Costs and Losses
2. Costs and VA/VE
Cost structure
Loss structure
Potential VA/VE
Loss-costRelationship
Matrix
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 16 of 84
Total Product Cost
Raw material Cost Conversion Cost Employee Cost Fixed Cost
Tools
Sub-contract
Power
Freight Outward
Chemicals
Spares
Bought out service
HSD
Oils and lubricants
Packing Materials
Variable others
Div.Heads
Corp. over heads
Special revenue
Utilities & building
Travel & conveyance
Fixed others
Cost structure
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 17 of 84
Losses
Time losses Resource losses
New losses
Losses affectingavailability
Losses affecting performance rate
Energy losses
Tool loss
Yield loss
Sub-contract loss
Inventory loss
Bought out service loss
Premium freight loss
Customer complaint loss
Loss structure
Schedule downtime losses
Management losses
Job change time loss
Breakdown loss
Losses affecting quality rate
16 major losses
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 18 of 84
VA/VE Improvements
Design VA/VE
Process VA/VE
Machine Output VA/VE
Labour Productivity VA/VE
Raw Material
Tools
Eliminate
Combine
Reduce
Simplify
Speed-up
Cycle Time Reduction
Multi Cavity
Enhance equipment capacity
Lunch Time Style Running
Automation
Single Piece Flow Lines
Lunch Time Running
Potential VA/VE improvements
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 19 of 84
Loss-cost relationship matrix
Relationship Rating Scale : 1 = Weak , 5 = Strong
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 20 of 84
Methodology for cost reduction
Loss reductionsand
VA/VE improvements
target
Evaluation of loss-cost valuesand
fixing targets for
Loss reductionsand
VA/VE improvements
Loss-costRelationship
Matrix
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 21 of 84
Loss-cost evaluation and setting targets
Yield Loss
Tool Loss
Energy Loss
J/C Loss
Tool VA/VE
Energy VA/VE
M/C Output VA/VE
Labour Productivity
VA/VE
BM 18% 20% 250 KWh/MT 275 mts. 490
Rs/MT 80
Rs/MT 412
Rs/MT 83 Rs/MT
BM Target Savings Target 8% 5% 100 KWh/MT 75 mts. 1097
Rs/MT 250
Rs/MT1238
Rs/MT 304 Rs/MT
RM cost 38,919 29,189 9,730 5 1 1 1 1 1 1 1
Tool cost 3,918 2,351 1,567 1 5 1 2 4 1 1 1
Energy cost 3,949 2,947 1,002 1 1 5 1 1 3 2 1
Fixed cost 15,877 9,609 6,268 1 1 1 3 1 1 4 1
Employee cost 7,600 6,080 1,520 1 1 1 1 1 1 1 5
Rs./MTMajor Cost Elements
Significant Losses and VA/VE
Losses VA/VE improvements
Relationship Rating Scale : 1 = Weak , 5 = Strong
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 22 of 84
Yield loss (loss no. 16) reduction
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 23 of 84
0
50
100
150
200
250
MT
MT 196 38 21 17 10 10 8
Process scrap Defect Loss Inventory
LossSetting Scrap Assorted PS En bit los Testing
Scrap
Yield loss elements
Selected for further analysis
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 24 of 84
0
20
40
60
80
100
120
140
MT
MT 120 76
Nut Process scrap Bolt Proces scrap
Yield loss elements
63%
37%
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 25 of 84
Trim BurrMachining BurrSlug Tapping swarf
Burrless forgingForge to final shape
Reduce Machining stock
Reduce slug thickness
Piercing in forging
Burrless Tapping
Grinding swarf
Reduce Grinding stock
Methodology for process scrap reduction
Process scrap reduction
Nut Bolt/Screws
Reduce Face machining
Reduce Bore machining
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 26 of 84
Slug Make to net shape
Make to near shape
I C I C I C
Reduce Slug 45 34 - - - -
Reduce Face machining - - 10 4 12 5
Reduce bore machining 7 3 18 12 19 12
Total 52 37 28 16 31 17
I - Identified 111
C - Completed 70
Activity
Elements
Kaizen implementation matrix
Process scrap reduction in nuts
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 27 of 84
BEFOREBEFOREAFTERAFTER
Sample Kaizen
25.0 mm
25.0 mm
RM wt. 96.0 gms RM wt.85.0 gms
New spring loaded die
Process scrap reduction in nuts
(Yield loss)
Yield = 79% Yield = 89.2%
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 28 of 84
Process scrap reduction - Nut
15
17
19
21
23
25
27
29
%
Yield Loss% 26 25.2 24.8 24.4 25 23 22.6 21.8 22 21.2 19
Tgt. 26 16
1998-99 1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 - I
2008-09 - II
Better
26%
19%
28% Reduction
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 29 of 84
Formed version
Make to net shape
Make to near shape
I C I C I C
Eliminate Trim burr 48 32 - - - -
Reduce OD grinding - - 15 8 26 16
Reduce collar machining - - 13 5 22 14
Total 48 32 28 13 48 30
I - Identified 124
C - Completed 75
Activity
Elements
Kaizen implementation matrix
Process scrap reduction in bolts
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 30 of 84
5
7
9
11
13
15
17
19
%
Yield Loss% 16.8 16.4 15.8 15.5 15.1 14.5 13.2 11.5 10.4 9.5 8
Tgt. 16.8 6
1998-99 1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 - I 2008-09 - II
16.8%
8%
Process scrap reduction - Bolt
Better
55% Reduction
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 31 of 84
0
2
4
6
8
10
12
14
16
18
20 %
Yield Loss% 17.8 17 16.1 15.8 14.9 14.5 13 12 11.5 10.4 9.7
Tgt. 17.8 8
1998-99 1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09-I 2008-09-II
17.8%
9.7%
Total yield loss reduction – Krishnapuram plant
45% Reduction
Better
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 32 of 84
25000
27000
29000
31000
33000
35000
37000
39000
Rs./MT
Cost 38918 38440 38012 37586 36980 35840 34980 34012 33856 32988 31586
Tgt. 38918 29189
1998-99 1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 - I 2008-09 - II
Resultant RM cost reduction – Krishnapuram plant
19% Reduction
Better
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 33 of 84
Tool VA/VE improvements
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 34 of 84
Methodology for Tool VA/VE improvements
Tool life improvement Tool Manufacturing improvement
Identify high consumption /value tools
Design improvement
Using higher grade material for tool
Improved surface coating for tool
Re-cycling
Analysis
Identify design weakness
Optimize tool design
Manufacturing cycle time reduction
Tool VA/VE improvements
Using low cost material
Substitute of low cost material in non working area
Improving the surface finish by changing process sequence
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 35 of 84
0
200
400
600
800
1,000
1,200
1,400
COST
Rs./
MT
Rs./MT 1,250 940 786 587 355
STEEL TOOLS CARBIDES ROLLING DIES TAPS OTHERS
Tool cost element-wise
Selected for further analysis
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 36 of 84
0
50
100
150
200
250
300
350
CO
ST R
s./M
T
Rs./MT 305 245 205 155 150 140 50
Piercing Pin Trim dies Heading Insert
Nut forming insert Punches Dies OTHERS
Tool cost element-wise
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 37 of 84
Tool VA/VE improvements – Steel tools
Tool manufacturing Design Recycling
I C I C I CPiercing Pin - - 18 8 12 8Trim Dies 11 9 - - 48 36Heading Inserts 6 3Nut Forming Dies 8 4 - -Bolt Forming Dies 4 2 - - 48 34Punches - - - - 4 3Common tools - - 10 6 55 33Total 23 15 34 17 167 114I - Identified 224C - Completed 146
Tool Category
Theme
Kaizen implementation matrix
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 38 of 84
Phase 1 Phase 1 -- ImprovementImprovement
Split design with common material (HSS)
Phase 2 Phase 2 -- ImprovementImprovementSplit design with ‘LoC’ material
Sample Kaizen – Split design
Tool VA/VE improvements – Piercing pin
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 39 of 84
0
5000
10000
15000
20000
25000
1.6D 1.5D 1.4D 1.3D 1.2D 1.1D 1D 0.9D 0.8D 0.7D
Length
No s
Failure mode: Buckling Failure mode:
Breakage
Optimum length: 1.1D to 1.3D
Result :
Tool cost savings up to Rs 1.2 million / Year ( 3.5 million yen/ Year).
Tool VA/VE improvements – Piercing pinLength optimization
L
D
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 40 of 84
Tool manufacturing Design Recycling
I C I C I CSteel tools 23 18 34 24 167 132Carbides - - 6 6 48 33Rolling Dies 4 2 - - - -Taps - - 7 4 - -Other tools - - 10 5 55 38
Total 27 20 57 39 270 203I - Identified 354C - Completed 262
Tool Category
Theme
Tool VA/VE improvements – All Tools Kaizen implementation matrix
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 41 of 84
400
600
800
1000
1200
Rs./MT
Cost / MT 490 520 590 610 670 697 720 786 840 870 928Target 490 1097
1998-99 1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09- I
2008-09- II
928
490
Cost savings through Tool VA/VE improvements
89% Improvement
Better
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 42 of 84
0
500
1000
1500
2000
2500
3000
3500
4000
4500
Rs./MT
Cost / MT 3918 3840 3750 3610 3560 3420 3315 3150 3010 2850 2480Target 3918 2351
1998-99 1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09- I
2008-09- II
Resultant tool cost reduction – Krishnapuram plant
34% Reduction
Better
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 43 of 84
Labour productivity VA/VE improvements
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 44 of 84
Labour productivity VA/VE improvements methodology
Labour productivityVA/VE Improvement
Lunch time style running
Automation Single piece flow lines
Coupling of machines
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 45 of 84
Lunch Time Style Running (LTSR)
An idea to increase labour productivity
Uses multi-machine operation
Single-piece flow conveyors and coupling of machines
Maximizes man-machine engagement
Layout changes
Focuses on line organization loss
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 46 of 84
Lunch Time Style Running
Perfect Cell
Perfect Lines
Multi LineOperation
Information System Support Team
Perfect Machines Coupling of Machines
Zero 1A/1B
Zero Defects
Zero Minor Stops
TPM Part - 1
TPM Part - 2
Methodology for Lunch Time “STYLE” Running
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 47 of 84
F RFORGING MACHINE ROLLING MACHINE OPERATOR
PRE-TPM TPM Part 1 TPM Part 2
6 Machines
6 Operators
Lunch Time stop
Machine concept
3 Lines
3 Operators
Regular : 3 Op & Lunch Time :1 Op.
Line concept
1 Cell
1 Operator
Regular, Lunch Time : 1 Op.
Cell concept
Journey to Lunch Time Style Running
LUNCH TIME STOPPING LUNCH TIME RUNNING LUNCH TIME STYLE RUNNING
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 48 of 84
Forging machine
Rolling machineOperator 1
Line 1Line 3 Line 2
Operator 2Operator 3
Problem / present statusWe have 3 lines of forging and rolling which are coupled
Each line has got a dedicated operator
Labour productivity is low
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 49 of 84
Countermeasures
Eliminate loading pits, output carrying conveyors and
vibratory feeders
Replace bulk feeding conveyors to Single-piece flow conveyors
Re-layout to minimize operator movement
Release other two operators for support / kaizen team
Introduce information system between operator and
support / kaizen team
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 50 of 84
MODIFIED LAYOUT
Line 1Line 3 Line 2
Operator 3 Operator 2 Operator 1
Operator 1
BEFORE LAYOUT
Lunch Time Style RunningSample Kaizen – 84S1, 84S2 and 84S 3
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 51 of 84
Responsibilities for Operator and Support teamOPERATOR RESPONSIBLE FOR ALL ACTIVITIES DONE ON ROUTINE BASIS
SUPPORT TEAM RESPONSIBLE FOR EXTERNAL AND SPECIAL ACTIVITIES
Lunch Time Style Running
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 52 of 84
Support required from Supervisor/Manager
Support required from Kaizen Team
Machine is in Running
Light Signal with AlarmAudio
LTSR - Information system
Information system
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 53 of 84
Result
100
213
639
0
200
400
600
800
Index 100 213 639
Pre-TPM TPM Part 1 TPM Part 2
Labour productivity index
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 54 of 84
Benefits
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 55 of 84
0
50
100
150
200
250
300
350
Rs./MT
Cost / MT 83 92 102 108 118 126 132 138 145 168 243Target 83 304
1998-99 1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09- I
2008-09- II
83
243
260%
BetterCost savings through labour productivity VA/VE improvements
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 56 of 84
5500
6000
6500
7000
7500
8000RS/MT
Cost 7600 7520 7410 7205 7180 6950 6770 6620 6520 6490 6320
Tgt. 7600 6080
1998-99 1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 - I 2008-09 - II
Better
Resultant employee cost reduction – Krishnapuram plant
17 % Reduction
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 57 of 84
Total product cost reduction – Krishnapuram plant
100
8273 70
0
20
40
60
80
100
%
Product cost % 100 82 73 70
BM (1998-99) Consistency (2004-05) Current (2008-09) Target
18% 27%30%
Against the target cost reduction of 30%, we achieved 27% so far.
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 58 of 84
TPMPart 1
TPMPart 2
It is wider!
It is higher!!
It is much bigger!!!
To Sum up
SFL – Krishnapuram Kobetsu Kaizen
SUNFAST TPM 59 of 84
Thank YouThank You