Tpm Wabco-tvs (India) Ltd

TPM as organizational motivator bby

P. KaniappanWhole Time DirectorWABCO-TVS ( INDIA ) LTD.WABCO TVS ( INDIA ) LTD.

Company profileCompany profile

Pl t & d tPlants & products

Customers

ABOUT TVS

• Established in 1911

• Vehicle dealership and parts distribution

• Passenger Bus and Freight Service

• Early innovators in operations and maintenanceTV Sundram Iyengar

• TVS : Trust, Value, Service

History of TVS

WABCO-TVS (INDIA) LIMITED( )Sundaram – Clayton Limited was established in 1962 as a joint venture

with Clayton Dewandre UK ( Now WABCO Vehicle Control Systems)

• The Brakes Division of Sundaram-Clayton Limited has now become a separate company WABCO TVS (INDIA) Limited On 3rd Jun’09separate company, WABCO-TVS (INDIA) Limited. On 3rd Jun 09 WABCO raised its ownership position to 75% equity investment and balance to public

• WABCO-TVS has three manufacturing sites (located at Chennai, Jamshedpur and Mahindra City)Jamshedpur and Mahindra City)

… over 40 years of service to the Indian automotive industry

WABCO-TVS PLANTSLocation map

Ambattur (1058 employees) ● Catering to the requirements

Location map

of Domestic market

Jamshedpur (108 employees)● Catering to the requirements

of Tata Motorsof Tata Motors

Mahindra World City (170 employees)(170 employees)

● Catering to the requirements of WABCO

Multi-plant operations

Ambattur plant Products

Complete system solution provider

Mahindra World City plant

Crankshaft

Crankcase Brake chamber

Vacuum pump bodyNumber of employees : 170

Production from MWC plant commenced from Jan’08

Jamshedpur plant

Sales from Jamshedpur plant commenced on Oct’07

OEM - CUSTOMERS

T t l E l I l tTotal Employee Involvement

Suggestions and QC participationMotivation Results – TEIResults TEI

Appreciation in company news letter Appreciation for more number of

Total employee involvement

for Best suggestion of the month suggestions by WTD

Appreciation in the gate meeting by WTD for best QCCby WTD for best QCC

Published in company news letterletter.

Presentation by operators about JH activities in his cell

Presentation by team leader on JH activities in his cell

Appreciation to Operator by miharasan for Best JH activities in his cell.

Appreciation to team leader by Miharasan for best JH activities in his cell

Rambo QC circle won 1st

prize in ACMA state levelprize in ACMA state level competition

Narmadha QC circle won parNarmadha QC circle won par excellence award from QCFI regional level competition

100

Suggestion Participation %

100

CFT/SIT Participation %

100

60

80

100

ntag

e

100

60

80

100

ntag

e

20

40

60

Perc

e

20

40

60

Perc

e

QCC participation %

20'01-02 '02-03 '03-04 '04-05 '05-06 '06-07 '07-08 '08-09

20'01-02 '02-03 '03-04 '04-05 '05-06 '06-07 '07-08 '08-09

100

80

100

age

40

60

Perc

enta

20'01-02 '02-03 '03-04 '04-05 '05-06 '06-07 '07-08 '08-09

5S k P ti5S work Practices

See through layout & Visual factory Motivation Pre fixed locations – shop floor 5 S – Office area5 S Office area My Line / My Machine

See through Layout & Visual factory5S work practices

Dedicated containers - easy for identification and trace ability

Pre fixed location – Contd….

Pre fixed location – Office area My Area

Red Tag tree Fixed point photo Pre – fixed location

Inside the drawer

MY LINE

MY LINE CONCEPT -

Every cell / line owned by team leadersy

MY MACHINE

MY MACHINE CONCEPT -

Machines owned by operators

C t D l tCompetency Development

Team leader – An Example Operator - An Example Kaizen done by operatorKaizen done by operator Motivation

Team leader competency development

Team leaders are the first level supervisors, above the operators.

Their competency improvement is important to sustain the benefits of TPM.

Team leader competency development - Continued

Technical skills and soft skills training planned through external agenciesTechnical skills training on Hydraulics, Pneumatics, Drives have been planned through CVAT

80T1 T1

Pre test scores

20

40

60

80T2

T3T9

T10

406080

100T2

T3T9

T10

0

20 T3

T4T8

T9

020

T4T8

T5

T6

T7 T5

T6

T7Post test scores

Comparison of pre and post training evaluation scores of Hydraulics and Pneumatics training programme at CVAT

Hydraulics Pneumatics

Additional competencies to take up next higher role Job rotation to Machine shopAdditional competencies to take up next higher role – Job rotation to Machine shop, Assembly shop, Maintenance, Quality assurance

125

150 Elemental Mapping 82

100

82 80

6378

50

75

100

82 80 78

50

75

Tim

e in

sec

s

6356

12 17 2012

0

25

Opn 020 -Face,

Groove,Bore &

Chamfer

Opn 030 -Face,

Groove,Bore &

Chamfer

Opn 040 -Drill,

Spotface,Chamfer &

Tap

Opn 050 -Drill,

Spotface,Chamfer &

Tap

Opn060 -Tap 4 Holes

Opn 080 -Drill & Tap

2 Holes

Opn 090 -Washing

AirCleaning

Manualwork 0

25

Opn No 020 Opn No 030 Manual workcontent

MethodologyGrasp the present status

Identify the NVA Elemental mapping

Methodology

Manual NVA Machine NVA

Brainstorm and find out NVA reduction in the bottleneck

Elemental mapping

Manual work reduction kaizens machine

Fabricate and install the kaizens Tooling improvements

Check for results and implement

Training and standardization

Tryout

Check and measure

Implement

Standardize P

DC

A

Company apprentice training process

Company apprentice is the future operator of the company

Their competency improvement isTheir competency improvement is focused to achieve zero defect, zero loss and zero scrap and waste

Kaizen Theme : Easy to Clean Kaizen Idea :Provide Localized guardKAIZEN Done by OperatorKAIZEN Done by Operator

Before After Benefits Dept : Valve 2Machine :08 87 05

Cleaning time is reduced from 5mins to 1mins

Difficult to Clean the Fixture Easy to clean the Fixture

1minscleaning time

5

4

5

11

2

3

time

in m

ins

Coolant & burr not splashes around the fixture

Coolant & burr splashes around the Fixture

0

B efo re A fter

Kaizen Theme : Easy to Clean Kaizen Idea :Provide Localized guard

KAIZEN Done by OperatorKAIZEN Done by Operator

Before After Benefits

Dept : Valve 2Machine : 085819

Cleaning time is reduced from 5 min to 1 min

Difficult to Clean the FixtureCoolant & burr splashes around the Fixture

Easy to clean the Fixture Coolant & burr splashes Avoided

Cleaning time

5

46

n m

ins

1

02

Before After

Tim

e in

Appreciation for Operator

Appreciation for OperatorAppreciation for Operator

Appreciation for Operator

Appreciation by WTD in gate meeting

Operator receives a prize for best kaizen activity in his cell

Appreciation for Operator

Best suggestion award winning operator , explains his suggestion detail in the monthly gate meeting

M d l ll ti itiModel cell activities

JH Step 0 , 1 , 2 & 3 Model cell – Results

Step 0 -Awareness Program

To start Jishu Hozen an awareness program was conducted in classroom forall circle members to explain,

The need of Jishu hozen activity cleaning,lubrication and inspection toestablish the Basic condition of the Machines.

The safety points to be followed in connection with initial cleaning.

Machine through cleaning by operators

RED FUGAI

STEP – 1 - Initial Cleaning and Abnormality findings

717075

RED FUGAI

WHITE FUGAIFugai tags per Employee CUM FUGAI

59

35

60 58

51

455055606570

gai s

CUM. FUGAI

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Employees

Kaizen Theme : Source of Contamination Kaizen Idea : Multiple Filtration

Before After Benefits Coolant tank contaminationEliminated.Cleaning time of 30 mins /

shift eliminated

Coolant Tank Contaminated with Burr / Chips

Provide Multiple Filtration Coolant tank

shift eliminatedConveyor motor power saving

Rs. 1200 / month.Coolant Consumption

reduced by 10 Lts/ Monthreduced by 10 Lts/ Month

Scope for HorizontalDeployment : 47

Completed : 6Coolant Tank Contamination with Burr Multiple Coolant Filtration

Kaizen Theme : Wet to dry Kaizen Idea : Localised Cover

Before After Benefits

1. Reduce cleaning timefrom 15 minutes to 2 Minutes2 No spillage of burr and

Coolant splash during machining on the floor

Provided localised cover to avoid coolant splash 2. No spillage of burr and

coolant on the floor3. Better house keeping

machining on the floor to avoid coolant splashduring machining

Scope for HorizontalDeployment :

SPM machines wherevermanual door is there

Coolant Spillage Localised Cover

Step 3 - CLIA Check SheetC – Cleaning / L – Lubrication / I – Inspection / A – Adjustment g p j

OLE trend

8587

90

100 35%

EN

TAG

E

72

78

82

70

80

IN P

ER

CE

6006-07 07-08 08-09 09 Q1 09 Q2

8000 Process rejections

57025300

6000

2696

2000

4000 96%

800250

005-06 06-07 07-08 08-09 09 Q1 09 Q2

Awards & Recognitions

AWARDS AND RECOGNITIONS 1998 Deming Application Prize

First Indian company to win the coveted Deming prize

2002 Japan Quality Medal

First Indian company and Second company outsideFirst Indian company and Second company outside

Japan to win the Japan Quality Medal

2002 ACMA award for technology

2003 ACMA Gold trophy for “Manufacturing excellence”

AWARDS AND RECOGNITIONS 2004 Tata Cummins certificate for “Commendable efforts in Value

Engineering and Cost Reduction”

2005 Frost & Sullivan, India manufacturing excellence Overall Gold award

2006 Eicher Motors certificate for “Value Engineering Support, Vendor Managed Inventory and State-of-the-art Design and TestingManaged Inventory and State-of-the-art Design and Testing Facilities”

2007 Tata Cummins certificate for “Excellent Support in New Product Introduction” and “Best Cost Reduction”

AWARDS AND RECOGNITIONS 2007 Frost & Sullivan, India manufacturing excellence Super

Platinum award

2007 JIPM – TPM Category 1 award

2008 TATA Motors certified for “Consistently maintaining Zero PPM over three years”Co s ste t y a ta g e o o e t ee yea s

2008 VOLVO Eicher Commercial Vehicles Vendor Meet – 2008 –“Best Quality Vendor”

AWARDS AND RECOGNITIONS 2008 TATA Motors Vendor Meet – 2008

– “Excellence in Quality”

2008 TATA Motors Vendor Meet – 20082008 TATA Motors Vendor Meet – 2008 – “Recognition of enduring relationship”

2009 ACMA Gold Trophy for “Manufacturing Excellence”

AWARDS AND RECOGNITIONS

2007 Frost & Sullivan, India manufacturing excellence Super Platinum award

2007 JIPM – TPM Category 1 award

2008 TATA M t tifi d f2008 TATA Motors certified for “Consistently maintaining Zero PPM over three years”

• 2004: TATA Cummins certificate for “Commendable efforts in Value Engineering and Cost Reduction”

• 2006: Eicher Motors certificate for “Value Engineering Support, Vendor Managed Inventory and State of the Art Design and

“Over the past several years, the management and workforce at the WABCO-TVS factory in Chennai have successfully implemented lean production Vendor Managed Inventory and State-of-the-Art Design and

Testing Facilities”

• 2008: TATA Motors, Jamshedpur : Award for Excellent Quality –Zero PPM for 3 successive years

• 2008: Eicher Motors Award for Best Overall Performance

y p pmethods while demonstrating the necessary leadership behavior to become as good as any manufacturing operation outside of Toyota City” saidoperation outside of Toyota City said Dr. Womack. “The factory team in Chennai has done a brilliant job of gathering lean knowledge and then incorporating it into their manufacturing system from policy deployment to logistics, making an impressive achievement.”

James P. Womack, Chairman and Founder, Lean Enterprise Institute

- 2008