TPM Progress Review

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15 Νοε 2013 (πριν από 3 χρόνια και 11 μήνες)

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TPM Progress Review

Kandakure Engineering
Pvt

Ltd

Dhananjay

Agenda


Summary of Business & SOB


Quality


Delivery


Development Lead Time


JH Implementation Status


Loss Monitoring & Reduction Actions


Summary of Business Growth Plan


Kandakure Engineering
Pvt

Ltd

Dhananjay

Varroc

100%

12.39%

13.03%

4.18%

2.32%

0.78%

5
15
20
3.37
14.16
14.91
0
50
2010
-
11
2011
-
12
2012
-
13
Target
Achived
Up to
Dec
12
Dhananjay

RIPL


KAPL


TOWER

DE

DAP

8.05%

31.26%

TPM

plant
Targets & Status

Parameters

Benchm
ark

Avg.

Targets

June
-
12

July
-
12

Aug
-
12


Sep
-
12


Oct
-
12

Nov
-
12

Dec
-
12

Status

p

Out put / Hour


4830


> 20%
Up

5581

6144

5343

5246

6503

7106

6641


Achieved

Q

Customer
Complaints
(Occurrence) (Nos.)

-
8
-

0

04

05

12

10

02

3

2

Not
Achieved

Customer complaint
(PPM)

1996

0

865

850

933

604

680

483

0

Achieved

In
-
house Rejection
(PPM)

1450

50

870

534

1456

1190

980

986

892

Not
Achieved

C

Cost of
Manufacturing (Rs)

----

--

-

-

-

-

-

-

--

--

D

Delivery Adherence
(%)

100

100%

95%

95%

95%

95%

98%

92%

98%


Not
Achieved

S

Accidents
-

Major
(Nos. / Month)

1

0

01

00

0

0

0

0

0


Achieved

M

Nos. of Kaizen /
Employee / Month
(Nos.)

0.33


1

0.31

0.7

0.78

0.8

0.85

0.83

0.84

(Not
Achieved )

Dhananjay

Quality

Dhananjay

Customer Complaint Quantity

Target : 0

5
3
4
5
12
10
2
3
2
0
2
4
6
8
10
12
14
Apr-12
Jun-12
Aug-12
Oct-12
Dec-12
Occurance
Varroc group

Dhananjay

Sr.No.
Complaint
raised on date
Name of the
customer
Name of the
Component
Nature of the
complaint
Remark
Status
1
01.12.12
DE
Not Reduce
Under Cut
Action Plan submit
Under Monitaring
3
17.12.12
DE
Lamination B&C
Burr
Resharpning pending
Corrected
Customer Complaints for the Month Oct-2012
Dhananjay

Customer Complaints PPM

Target : 0

490

452

865

850

933

604

680

483.00

0

0
100
200
300
400
500
600
700
800
900
1000
Apr-12
May-
12
Jun-12
Jul-12
Aug-12
Sep-12
Oct-12
Nov-12
Dec-12
Axis Title

PPM

PPM
Varroc group

Dhananjay

Customer Complaint Phenomena

Target : 0

Dhananjay

0

0

0

0

0

0

0

0

0

1

0

0

0

1

0

0

0

0

0

0

0

0

0

0

0

0

0

1

0

0

0

0

1

1

0

0

0

1

0

0

0

1

1

1

0

0

0

1

0

0

1

0

1

0

0

0

0

0

3

4

0

0

1

1

2

2

3

2

0

0

1

1

0

1

1

1

3

1

0

0

0

0

0

0

0

2

1

0

0

0

0

0

1

1

1

1

0

0

0

0

0

0

0

0

0

0

0

0

0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
Apr'12
May'12
Jun'12
Jul'12
Aug-12
Sep-12
Oct,12
Nov-12
Dec-12
Height oversize
ID Oversize
OD Undersize
Hole shift/Missing Emboss
Raw material thickness
Gap gauge not ok / Taper
Burr at ID/Dust/Rusty
Under cut
Line mark
Dent/Damage
Lamination Shifting
Stack thickness U/s
Customer Complaint Phenomena

Target : 0

Dhananjay

1

0

0

0

1

0

0

0

0

0
0.2
0.4
0.6
0.8
1
1.2
Apr'12
May'12
Jun'12
Jul'12
Aug-12
Sep-12
Oct,12
Nov-12
Dec-12
OD Undersize
ID Oversize
Height oversize
Customer Complaint Phenomena

Target : 0

Dhananjay

0
0.5
1
1.5
2
2.5
3
3.5
Apr'12
May'12
Jun'12
Jul'12
Aug-12
Sep-12
Oct,12
Nov-12
Dec-12
Gap gauge not ok /
Taper
Raw material
thickness
Hole shift/Missing
Emboss
Customer Complaint Phenomena

Target : 0

Dhananjay

0
1
2
3
4
5
6
7
8
9
Apr'12
May'12
Jun'12
Jul'12
Aug-12
Sep-12
Oct,12
Nov-12
Dec-12
Line mark
Under cut
Burr at ID/Dust/Rusty
Customer Complaint Phenomena

Target : 0

Dhananjay

0
0.5
1
1.5
2
2.5
3
3.5
Apr'12
May'12
Jun'12
Jul'12
Aug-12
Sep-12
Oct,12
Nov-12
Dec-12
Stack thickness
U/s
Lamination
Shifting
Dent/Damage
Action Plan


Customer Complaints

Dhananjay

Sr No
Date
Problem
Defect /
Pain
Problem
Defect /
Pain
Repeatat
ive /
New
Problem
Related
To
Custome
r / My
Company
Root
Cause
Correctiv
e action
Sustaina
nce
action
Ownersh
ip By
Remark
Oct-12
Nov-12
Dec-12
Nov-12
Dec-12
Jan-13
1
01.12.12
Not
Reduce
Under
cut
Repeatat
ive
Custome
r
0
0
1
Air
supply
enterapt
added
pressure
switch
0
0
Maintain
the
record in
M/s
histry
card
Mr.Gade
2
17.12.12
Burr in
laminatio
n B & C
New
Custome
r
0
0
1
tool not
resharp
on time
Tool
resharpin
g done
0
0
Maintain
the
record in
M/s tool
histry
card
Mr.Sand
u
Effectiveness Of Corrective Actions / Improvement & Sustenance Format
Past 3 Months data
Result of next three Months
data
Inhouse Rejection
-

PPM

Target : 0

560

570

870

534

1456

1190

980

986

892

0
200
400
600
800
1000
1200
1400
1600
Apr-12
Jun-12
Aug-12
Oct-12
Dec-12
PPM
Dhananjay

2

4

8

6

72

528

312

220

275

12

8

528

210

388

110

395

383

0
100
200
300
400
500
600
PPM
-
Dec
-
12

Dec-12
In
-
house Rejection
-

Phenomena

Dhananjay

Action Plan


In house Rejection

Dhananjay

Problem
Problem
Problem
Related To
Defect /
Pain /
Phenomena
Defect /
Pain /
Phenomena
Customer /
My
Company
Repeatative
/ New
Aug-12
Sep-12
Oct-12
Nov-12
Dec
Jan
1
Under cut-
115
Repeatati v
e
My
Company
658
524
908
Coi l
mi ssfeed
NC feeder
add to
prevent
the
mi ssfeed
the coi l
623
528
Dai l y JH &
mai ntai n
the record
Mr.Garad
Under
moni tari n
g
2
Under cut-
3w4s
New
My
Company
210
1248
659
D-coi l er
motor
i ssue
D-Coi l er
motor
corrected
237
126
Motor
connected
wi th
3phase
Mr.Kapate
Compl eted
3
Li ne mark-
115
New
Suppl i er
112
208
582
R/m Issue
Informed
to
suppl i er_s
uppl i er
acti on
taken
265
142
Suppl i er
acti on
pl an
Mr.Shyam
Lol ewar
Compl eted
4
Dent/Dam
age
Repeatati v
e
My
Company
958
1028
782
Feeder
Issue-
mi ssfeed
Pressure
Gauge
added
626
528
Dai l y JH &
mai ntai n
the record
Mr.gade/h
ade
Compl eted
5
Underr cut-
F.A k-70
Repeatati v
e
My
Company
526
826
711
Feeder
Issue-
mi ssfeed
Pressure
Gauge
added
166
52
Dai l y JH &
mai ntai n
the record
Mr.gade/h
ade
Compl eted
Effectiveness Of Corrective Actions / Improvement & Sustenance Format
Sr No
Date
Past 3 Months data
Root Cause
Corrective
action
Result of next three Months data
Sustainance
action
Ownership
By
Remark
AFTER

BEFORE

Zone name/no :
-

Top Arm cell

15.12.2012

Benefits :
-

:
-

setting time reduce and perpendicularity improve.

Problem Status
: U
-
Beam Forming Die
rectangular side support

Counter measure:
-

Triangular side
support provided


Improvement Sheet.

AFTER

BEFORE

Zone name/no :
-

Press Shop

30.12.2012

Benefits :
-

:
-
Safety & Easy to lift the material & time save for the same

Problem Status
:

No C
-
Hook

Counter measure:
-

C
-
Hook designed
for coil loading


Improvement Sheet.

No snap

AFTER

BEFORE

Zone name/no :
-

Press Shop

08.12.2012

Benefits :
-

:
-

Pitch setting & run out setting time save

Problem Status
:
Plain feeder

Counter measure:
-

NC Feeder added
on 80Ton Press machine


Improvement Sheet.

AFTER

BEFORE

Zone name/no
:
-

Press Shop..

13.12.2012

Benefits :
-

:
-
Productivity increases & easy to handling & no excess material flow

Problem Status
:
Machine not in single
flow

Counter measure:
-

Machine combine
for single piece flow for K
-
70 F.A.


Improvement Sheet.

No snap

Delivery

Dhananjay

94

96

95.5

96

97

96

98

97

98

92
93
94
95
96
97
98
99
Apr/12
May/12
Jun/12
Jul/12
Aug/12
Sep/12
Oct/12
Nov/12
Dec/12
%

%
Target : 100%

Dhananjay

Delivery

Development Lead Time

Dhananjay

Development


On Time Development

Parameter
s

Targ
et

Apr
12

May
12

Jun
12

Jul 12

Aug
12

Sep
12

Oct
12

Nov
12

Dec,1
2

No of S1

Sample
Submitted

31

4

3


3

5

10

3

3

2

2

No of S1
Sample
Accepted

27

4

2

1

5

9

3

3

2

2

Sample
Approval
1
st

Time %

87
%

100
%

66%

33%

100%

90%

100%

100%

100%

100%

Dhananjay

Development


First Time Right

Parameter
s

Targ
et

Apr
12

May
12

Jun
12

Jul 12

Aug1
2

Sep12

Oct
-
12

Nov
-
12

Dec,1
2

No of S1

Sample
Submitted

3

4

3



3

5

10

3

3

2

2

No of S1
Sample
Accepted

2

3

1

2

4

8

2

3

2

2

Sample
Approval
1
st

Time %

66.
67%

75

33 %

66%

80%

80%

66%

100%

100%

100%

Dhananjay

Month

Item

Reason For Rejection

Action

June
-
2012

Shoe
Welded

Result of liner

Bounding %
is 72 against 85%
-
due to
dimension issue i.e. Taper
0.25 against 0.2mm

Corrected

location of
shoe resting in Restrike
machine also shape
profile to Roller of
restrike machine

Jun
-
2012

U
-
Type

Bracket
K24A

Concentricity

observed
0.25 against 0.10

Threading is done in the

fixture

Jul
-
2012

R104 & JY

Core Pack

Run Out observed

0.35
against 0.10 & OD 91.6
-
0.2 observed 91.32

Blanking

tool to be
change from Compound
to Progressive

Aug
-
2012

U
-
Beam

Perpendicularity observed
0.19 against 0.10

Forming die locating pins
replaced

with Blocks for
more outer
referance

Action Taken For S2

JH Implementation Status

Dhananjay

JH Implementation Status

Sr No

Total No of
Machines /
Lines

Machines
/ Lines
Under JH
Step 1

Machines
/ Lines
Under JH
Step 2

Machines
/ Lines
Under JH
Step 3

Balance

Target
Date

1.

29

15

11

3

0

31.3.2013

Dhananjay

Loss Monitoring

Dhananjay

Losses

APR.12

MAY.12

JUN.12

JULY.12

AUG
-
12

SEP
-
12

OCT
-
12

Nov
-
12

Dec,12

Brekdown /
Equipment failure
losses

218

192

204

183

174

164

172

262

48

Setup &
Adjestment losses

184

192

178

186

163

146

143

138

124

Shut

Down

154

142

114

141

196

324

94

82

78

Minor stopeges

56

49

44

52

38

34

37

28

29

Inspection

&
Adjustment loss

102

98

83

94

77

54

49

42

31

Management loss

358

296

242

221

232

256

198

258

143


Loss Monitoring of Last
-

Apr12
-
OCT
12

Dhananjay

People Involvement

Dhananjay

Apr'12
May'12
Jun'12
Jul,12
Aug,12
Sep,12
Oct,12
Nov,12
Dec,12
QTY
58
53
56
62
56
58
60
72
74
58
53
56
62
56
58
60
72
74
0
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
Kaizen / Suggestions
Months
Kaizen

Target :

Dhananjay

Business Growth Plan

0
%

Dhananjay

Summary of Business Growth Plan

SALE


in
Crs

FY 12
-
13

Act

In Q1
Crs

Apr


Jun 12

Act in Q2
Crs

Jul


Sep 12

Act I
n Q3

Oct


Dec 12

19.16

4.39

4.31

6.21

Dhananjay

Summary of Business Growth Plan

Month

Target
in
Crs


Act in
Crs

Gap

Action

Responsibility

Target Date

Apr12

1
.55

1.47

0.18

Trying for

Additional business
with existng
customer.

Business with new
customer

Shaikh

May12

1
.55

1.43

0.31

Shaikh


Jun12

1
.55

1.5

0.33

Shaikh


Jul12

1
.6

1.46

0.47

Shaikh



Aug12

1
.6

1.43

0.2

Shaikh



Sep12

1
.6

1.42

0.38

Shaikh



Oct 12

1
.6

2.46



Shaikh



Nov12

1
.6

1.68



Shaikh

Dec,12

1.6

2.07

Total

19.16

14.92




Shaikh

Dhananjay