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9/25/2011
1
1 | Presentation Name Confidential—For Internal Use Only
Avery Dennison Offset TPM Implementation : Bangladesh
14 July 2011
> Iftekhar Aziz & Naynendu Bagchi
RBISAP / Bangladesh
2 | Presentation Name Confidential—For Internal Use Only
AgendaAgendaAgendaAgendaWhat is TPM??
History of TPM.
16 Major losses.
TPM 8 Pillars.
SWOT Analysis.
Limitations of our implementation.
Initiate implementation : Department & Losses Selection #Pareto analysis.
What are the KPIs??
How we start the journey.
Develop Project A3.
Base Line & Target Condition.
Yearly TPM calendar preparation.
PM1: Autonomous Maintenance checklist & tracking system for PM1.
Training and skill metrics development.
Setup time reduction help from setup time team.
Results.
Further action plans.
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3 | Presentation Name Confidential—For Internal Use Only
What is TPM??What is TPM??What is TPM??What is TPM??
T: Total
P: Productive
M: Maintenance & Management
Total Productive Maintenance & Management
combines the best features of productive &
preventive maintenance with innovative management
strategies and total employee involvement.
TPMTPM
4 | Presentation Name Confidential—For Internal Use Only
History of TPM.History of TPM.History of TPM.History of TPM.
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5 | Presentation Name Confidential—For Internal Use Only
16 Major losses.16 Major losses.16 Major losses.16 Major losses.
6 | Presentation Name Confidential—For Internal Use Only
TPM 8 Pillars.TPM 8 Pillars.TPM 8 Pillars.TPM 8 Pillars.
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7 | Presentation Name Confidential—For Internal Use Only
SWOT Analysis SWOT Analysis SWOT Analysis SWOT Analysis
Strengths� Management’s focus on TPM.� Platform team’s support.� Skilled manpower.� Department’s willingness for TPM.
Weakness� Operators’ mind setup.� Not having enough technical people.� Not having frequent audit system.� Unwillingness for Tags fill up.
Opportunities� Different m/c category.� Complex equipment parts.� Discussion on MDI.� Publishing success story.
Threats� Peak season higher order volume.� Procurement policies.� Root cause analysis of the Tags.� Regular follow up of PM1.
8 | Presentation Name Confidential—For Internal Use Only
Limitations of our implementation.Limitations of our implementation.Limitations of our implementation.Limitations of our implementation.
Implement TPM initially in the Offset.
Focusing on the Breakdown time loss only.
Implement TPM for the major machines.
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9 | Presentation Name Confidential—For Internal Use Only
Initiate implementation : Department & Loss Selection #Pareto analysisInitiate implementation : Department & Loss Selection #Pareto analysisInitiate implementation : Department & Loss Selection #Pareto analysisInitiate implementation : Department & Loss Selection #Pareto analysis
Loss Selection
∆ Shut down loss: Power failure.
∆ Management loss: Training/Meeting, waiting for instruction, waiting
for proof reading, no work.
∆ Operating motion loss: Job changing.
∆ Schedule down time loss: Day end cleaning.
∆ Logistics loss: Waiting for material, ink preparation
∆ Break down loss: Machine break down.
∆ Measurement/Adjustment loss: Trouble shooting.
10 | Presentation Name Confidential—For Internal Use Only
Initiate implementation : Department & Loss Selection #Pareto analysisInitiate implementation : Department & Loss Selection #Pareto analysisInitiate implementation : Department & Loss Selection #Pareto analysisInitiate implementation : Department & Loss Selection #Pareto analysis
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11 | Presentation Name Confidential—For Internal Use Only
What are the KPIs??What are the KPIs??What are the KPIs??What are the KPIs??
Trained Operators #
MTTR
MTBF
Breakdown TimeAvailability
UEE
Uptime
Uptime
Performance
Maintainability
Uptime
UEE
ScrapSetup Time
Multi Skill
12 | Presentation Name Confidential—For Internal Use Only
How we start the journeyHow we start the journeyHow we start the journeyHow we start the journey
Initiate Implementation
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13 | Presentation Name Confidential—For Internal Use Only
Develop Project A3Develop Project A3Develop Project A3Develop Project A3
14 | Presentation Name Confidential—For Internal Use Only
Base Line & Target ConditionBase Line & Target ConditionBase Line & Target ConditionBase Line & Target Condition
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15 | Presentation Name Confidential—For Internal Use Only
Yearly TPM calendar preparationYearly TPM calendar preparationYearly TPM calendar preparationYearly TPM calendar preparation
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SerialSerialSerialSerial M/C NoM/C NoM/C NoM/C No M/C NameM/C NameM/C NameM/C Name TPM StatusTPM StatusTPM StatusTPM Status1111 L 01L 01L 01L 01 GTO 4CGTO 4CGTO 4CGTO 4C2222 L 02L 02L 02L 02 GTO 4CGTO 4CGTO 4CGTO 4C3333 L 03L 03L 03L 03 GTO 2CGTO 2CGTO 2CGTO 2C4444 L 04L 04L 04L 04 GTO2CGTO2CGTO2CGTO2C5555 L 05L 05L 05L 05 QMQMQMQM----46464646----1C1C1C1C6666 L 23L 23L 23L 23 GTO 2CGTO 2CGTO 2CGTO 2C7777 L 24L 24L 24L 24 KORDKORDKORDKORD8888 L 25L 25L 25L 25 GTO 1CGTO 1CGTO 1CGTO 1C9999 L 29L 29L 29L 29 CD 74CD 74CD 74CD 7410101010 L 31L 31L 31L 31 GTO 2CGTO 2CGTO 2CGTO 2C11111111 L 48L 48L 48L 48 GTO 4CGTO 4CGTO 4CGTO 4C12121212 AD CD 74AD CD 74AD CD 74AD CD 74 AD CD 74AD CD 74AD CD 74AD CD 7413131313 SM 52SM 52SM 52SM 52 SM 52SM 52SM 52SM 5214141414 MOZMOZMOZMOZ MOZMOZMOZMOZTotal No of m/c : 14
TPM initiates taken : 13
TPM initiates missing : 1
TPM Completion TPM Completion TPM Completion TPM Completion
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17 | Presentation Name Confidential—For Internal Use Only
PM1: Autonomous Maintenance checklist & tracking system for PM1.PM1: Autonomous Maintenance checklist & tracking system for PM1.PM1: Autonomous Maintenance checklist & tracking system for PM1.PM1: Autonomous Maintenance checklist & tracking system for PM1.
18 | Presentation Name Confidential—For Internal Use Only
Training and skill metrics development.Training and skill metrics development.Training and skill metrics development.Training and skill metrics development.
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19 | Presentation Name Confidential—For Internal Use Only
Setup time reduction help from setup time team.Setup time reduction help from setup time team.Setup time reduction help from setup time team.Setup time reduction help from setup time team.
∏ Find out the base line
∏ Set the targeted time
∏ SOP from P & C
∏ SMED training for operators
∏ Explain SOP
∏ Implement SOP in local language
∏ Continuously monitor setup time
∏ Watch other site’s setup time
20 | Presentation Name Confidential—For Internal Use Only
Action FiguresAction FiguresAction FiguresAction Figures
Declaration from Top Management
TPM Introduction
TPM Kick Off
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21 | Presentation Name Confidential—For Internal Use Only
Initial briefing
Action FiguresAction FiguresAction FiguresAction Figures
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Action FiguresAction FiguresAction FiguresAction Figures
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Action FiguresAction FiguresAction FiguresAction Figures
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Action FiguresAction FiguresAction FiguresAction Figures
Before
After
Dust, Grease & Ink are everywhere which stuck into the m / c parts
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25 | Presentation Name Confidential—For Internal Use Only
Action FiguresAction FiguresAction FiguresAction Figures
Before
After
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Action FiguresAction FiguresAction FiguresAction Figures
Before
After
Cleaning is not easy as it sounds
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27 | Presentation Name Confidential—For Internal Use Only
After CleaningAfter CleaningAfter CleaningAfter Cleaning
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Brain stormingBrain stormingBrain stormingBrain storming
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TrainingTrainingTrainingTraining
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ResultsResultsResultsResults
Breakdown Time
MTBF & MTTRBase Line:
Unplanned Downtime,
mins/week: 5396
TPM trained operators: 0
MTBF, hr/week: 36.6
MTTR, hr/week: 4.13
Setup Time, mins: 58
Current Condition:
Unplanned Downtime,
mins/week: 2738
TPM trained operators: 50
MTBF, hr/week: 29.35
MTTR, hr/week: 3.1
Setup Time, mins: 39
Target Condition:
Unplanned Downtime,
mins/week: 4047
TPM trained operators: 100
MTBF, hr/week: 40
MTTR, hr/week: 3.5
Setup Time, mins: 30
Setup Time
Trained operator #
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31 | Presentation Name Confidential—For Internal Use Only
Schedule & Unscheduled Breakdown time contrastSchedule & Unscheduled Breakdown time contrastSchedule & Unscheduled Breakdown time contrastSchedule & Unscheduled Breakdown time contrast
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Unscheduled Breakdown time contrastUnscheduled Breakdown time contrastUnscheduled Breakdown time contrastUnscheduled Breakdown time contrast
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MTBF (Mean Time between Failure) contrastMTBF (Mean Time between Failure) contrastMTBF (Mean Time between Failure) contrastMTBF (Mean Time between Failure) contrast
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MTTR (Mean Time to Repair) contrastMTTR (Mean Time to Repair) contrastMTTR (Mean Time to Repair) contrastMTTR (Mean Time to Repair) contrast
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35 | Presentation Name Confidential—For Internal Use Only
Setup Time : Actual Vs TargetSetup Time : Actual Vs TargetSetup Time : Actual Vs TargetSetup Time : Actual Vs Target
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FuguaiFuguaiFuguaiFuguai TagsTagsTagsTags
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37 | Presentation Name Confidential—For Internal Use Only
Further action plans.Further action plans.Further action plans.Further action plans.
Initial cleaning schedule for Varimatrics, Die- cut,
Guillotine
PM 1 for SM 52, MOZ
PM 2 for GTO, CD 74
Maintenance checklist training for SM 52, MOZ
Spare parts management system
38 | Presentation Name Confidential—For Internal Use Only
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39 | Presentation Name Confidential—For Internal Use Only
© 2011 Avery Dennison Corporation. Al l r ights reserved. Avery Dennison and al l other Avery brands, product names and codes are trademarks of Avery Dennison Corporation. Al l
other brands and product names are trademarks of their respective owners. Fortune 500 is a trademark of Time, Inc. Personal and company names and other information on
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