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6.4.2 Weekly

Figure 9: Route map for weekly inspection

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6.5 TPM KAIZEN SHEETS

Figure 10: Tpm-kaizen idea sheet 1

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Figure 11: Tpm-kaizen idea sheet 2

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Figure 12: Tpm-kaizen idea sheet 3

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Figure 13: Tpm-kaizen idea sheet 4

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6.6 OEE CALCULATION

OEE FOR THE MONTH OF APRIL

Item Data

Shift Length 8hrx2shiftsx24days =

23040min.

Short Breaks 2 @ 15 min. = 30 min.

Meal Break 1 @ 30 min. = 30 min.

Down Time 2256 minutes

Ideal Run Rate 1 pieces per minute

Total Pieces 14348 pieces

Reject Pieces893 pieces

Table 5: Data for the month of April

Planned Production Time= [Shift Length - Breaks] = [23040 - 2880]= 20160 minutes

Operating Time= [Planned Production Time - Down Time] = [20160 - 2256] =

17904minutes

Good Pieces= [Total Pieces - Reject Pieces] = [14348 - 893] = 13455 pieces

Availability =Operating Time / Planned

Production Time

17904 minutes /20160minutes

0.89 (89%)

Performance =(Total Pieces / Operating Time) /

Ideal Run Rate

=(14348 pieces /17904 minutes) / 1

pieces per minute

= 0.82(82%)

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6.7 COST ANALYSIS:

COST ANALYSIS FOR THE MONTH OF FEBRUARY:

Revenue Quoted = Total productproduced x price per

piece

= 13850 x 80 = 1108000 Rupees

Actual revenue = Total no of Quality

product x price per

piece

= 12890 x 80 =1031200 Rupees

Loss due to

rejected

= Scraps x price per

piece

= 960 x 80 = 76800 Rupees

Loss Due To Downtime

DOWNTIME = 3960 minutes

Ideal run rate = 1 piece per minute

Products that

could have beenproduced during

downtime

Downtime x Ideal run

rate = 3960 X 1 = 3960 pieces

Revenue that

could have been

generated during

downtimePieces x rate per piece = 3960 X 80 =316800 Rupees

Table 7: Cost analysis for February

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COST ANALYSIS FOR THE MONTH OF APRIL:

Revenue Quoted = Total product

produced x price per

piece

= 14348 x 80 = 1147840 Rupees

Actual Revenue = Total no of Quality

product x price per

piece

=13455 x 80 =1076400 Rupees

Loss due to

rejected

= Scraps x price per

piece

= 893 x 80 = 71440 Rupees

Loss Due To Downtime

DOWNTIME = 2256 minutes

Ideal run rate = 1 piece per minute

products that

could have beenproduced during

downtime

Downtime x ideal run

rate = 2256 X 1 = 2256 pieces

revenue that couldhave been

generated during

downtimePieces x rupees = 2256 X 80 =180480 Rupees

Table 8: Cost analysis for April

A significant reduction in down time can be observed from the month ofFebruary to April.

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Conclusion

The press brake machine which did not have proper maintenance and was creating bottleneck in

the production, now has higher overall equipment effectiveness. Also noticeable is the reductionof defects in the samples.

TPM has also created awareness among the operators, a sense of responsibility and also

provided a safe working environment for them.

TPM has increased the availability of the machine due to good maintenance, has increased

revenue for the company and hence acts as a cost saving tool.

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References

1. Implementation of TPM- Steve Borris2. www.plant-tpm.com3. www.tpmclubofindia.com

http://www.plant-tpm.com/http://www.tpmclubofindia.com/http://www.tpmclubofindia.com/http://www.plant-tpm.com/