Implementation of TPM in the fine boring cell at wheel cylinder unit, brakes India, Madras

Abstract

Brakes India Ltd is a market leader in brake industry in India and has multimanufacturing locations. In the dynamic business scenario .customer satisfaction can be achieved through efficient production systems ,which in turn depends on the overall effectiveness of the machines available. To achieve this an attempt has been made to bring about a companywide TPM awareness and as a demonstration excercise implement Total Productive maintenance in the fine boring cell of the wheel cylinder unit of Brakes India Ltd, Madras .APPROACHAs a demonstration excercise, it was decided to choose Alfing four Spindle Fine boring machine at the wheel cylinder unit since it is handling more than 25 varities of wheel cylinders and any delay affects the customer line. The overall equipment effectiveness is a very significant ratio which captures the the following losses taking place in a production environment. Breakdown losses Setup Losses Speed Losses. Minor Stoppage Losses Process defects Startup losses The trend of the OEE calculated with the available data for the last seven months Show a variation between 39.48 to 51.37 between June'96 to Dec'96excluding the time lost due to no operator and material. Considering these losses also in to account, the OEE varies between 31.73 to 38.7%.The various factors influencing OEE such as breakdown times and setup times were analysed and steps to improve them have been identified. Also as part of daily autonomous maintenance by the operators, a work instruction has been prepared. The maintenance breakdown history for the last six years have been compiled problem wise to identify any problems of repeated nature. The details of the various calculations for the overall equipment efficiency and the trends are enclosed. FURTHER ACTIONS Setting targets for increased OEE after improvements through small group activities. Training the operators on the elementary maintenance activities. Establishing daily maintenance by the operators Bringing TPM awareness among operators. Integrating TPM activities with QS 9000 and ISO 9000 activities. Indian Institute of Management, Bangalore. A Project report on TPM at fine boring cell at wheel cylinder unit, Brakes India ,Madras RECOMMENDATIONS OEE trend to be monitored continuously and improvement targets to beset on the bottleneck machines. company wide TPM to be planned after establishing TPM in the fine boring cell.The different steps involved in the companywide TPM is given in detail in the literature survey.