Adbd Offset Tpm Implementation Program [Compatibility Mode]

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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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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

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History of TPM.History of TPM.History of TPM.History of TPM.

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16 Major losses.16 Major losses.16 Major losses.16 Major losses.

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TPM 8 Pillars.TPM 8 Pillars.TPM 8 Pillars.TPM 8 Pillars.

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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.

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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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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.

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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

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How we start the journeyHow we start the journeyHow we start the journeyHow we start the journey

Initiate Implementation

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Develop Project A3Develop Project A3Develop Project A3Develop Project A3

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Base Line & Target ConditionBase Line & Target ConditionBase Line & Target ConditionBase Line & Target Condition

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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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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.

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Training and skill metrics development.Training and skill metrics development.Training and skill metrics development.Training and skill metrics development.

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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

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Action FiguresAction FiguresAction FiguresAction Figures

Declaration from Top Management

TPM Introduction

TPM Kick Off

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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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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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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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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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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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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

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