kick off

Document Sample
kick off Powered By Docstoc
					              Uma Precision Limited (UPL)
Uma Precision Limited (UPL) was founded in 1979 to                RESULTS - TPM MODEL MACHINE :                                                                                              The Newsletter from TPM Club India
manufacture precision Assemblies, Systems and Machined            MEASURES PARAMETER                               UNIT        BEFORE               AFTER
parts. The company has evolved into group of companies at six              Production Rate                         Times       1                    2.03
locations in India.                                                                                                                                          Supplementary Newsletter                                        Volume 20                                       December 2006
                                                                           Production Achievement                  %           48.09                100
                                                                    P      OEE                                     %           48.10                96.35
The TPM Journey was started at Pimpri (Pune) plant in Nov-
2004 by deploying 1S-2S concept across the plant and TPM
                                                                           Break down frequency                    No.         5                    0                                                   TPM Kick Off & Progress
model machine activity on 4 selected machines.                         Q           Total defect                    No.         868                  0
                                                                       C           Cost machine / Month            Rupees      457.60               253.60
The implementation at these facility is being carried forward
under the guidance of Mr. Abdul Wadood, Counselor, TPM
                                                                                   Delivery Performance
                                                                                   Safety (Accident)
                                                                                                                                                                             Colgate Palmolive India Limited,
Club of India, CII by focusing on 4 pillars i.e Kobetsu Kaizen,
Jishu Hozen, Planned maintenance and Quality maintenance.
                                                                       M           Kaizen                          Nos. / Year 0                    89
After successful results on model machines TPM Kick-off                                                                                                      The Aurangabad Plant of Colgate Palmolive India Limited                    To celebrate this success and create momentum for Factory
ceremony was held on 24th Dec. 2005 to extend TPM activities                                                                                                 embraced TPM in November 2005.The products                                 wide deployment of TPM, TPM “Kick off” function was
across the plant. The kick-off ceremony began with lighting                                                                                                  manufactured here include Colgate Toothpowder and                          organized on 10 th of August, 2006 in the factory premises.
the auspicious lamp by dignitaries present, followed by                                                                                                      Palmolive Shave Cream.                                                     Senior Managers from the Colgate India Supply Chain including
                                                                                                              Opening of TPM Policy and mission
opening of TPM Policy and mission logo by Chairman Mr.                                                        logo by Mr. S. N. Kothari, DGM-Materials,                                                                                 Mr. Deepak Chhibba – Executive Vice President graced the
Madanlal Kankaria. All the employees took the TPM oath to                                                     Bajaj Auto Ltd. & Mr. Madanlal Kankaria,       The TPM journey here was started by selection of a “Manager
                                                                                                              Chairman, Uma Precision Ltd                                                                                               occasion along with Mr. Charles Pinto, our TPM Counselor. Mr. C
emphasize their total commitment to implement TPM activity                                                                                                   Model Machine” and practicing the “step by step” approach
                                                                                                                                                                                                                                        P Tripathi, Vice President – Works, Bajaj Auto Ltd., and Mr. R N
throughout the plant and to achieve the targets as outline in                                                                                                outlined in the four pillars; Jishu Hozen, Kobetzu Kaizen,
                                                                                                                                                                                                                                        Bagla, Chairman, Aurangabad Electricals, both eminent
the master plan by signing the targets indicative board.                                                                                                     Planned Maintenance and Quality Maintenance under the
                                                                  “Dahihandi” presented by group of                                                                                                                                     personalities from local TPM practicing industry, were the
                                                                  16 peoples to eliminate 16 losses.                                                         guidance of Mr. Charles Pinto-Counselor, TPM Club of India,
                                                                                                                                                                                                                                        Guests of Honour. Representatives of key vendors and service
The Chief guest Mr. S. N. Kothari , DGM -Materials, Mr. V.                                                                                                   CII. Targets were set under each of the TPM Measures such as
                                                                                                                                                                                                                                        providers were also present on this occasion.
Ramesh, Sr. Manager, Component Development , Bajaj Auto                                                                                                      Productivity (P), Quality (Q), Cost (C), Delivery (D), Safety (S),
Ltd., Mr. Raipurkar, DGM-Materials, Tata Motors                                                                                                              and Morale (M) and a time bound plan worked out to meet                    After the customary welcome song and lighting of lamp, Mr.
congratulated the team for achieving significant                                                                                                             these for the Manager Model Machine.                                       Deepak Chhibba unveiled the TPM Policy while Mr PRC Rao,
improvements in all performance indicators., Mr. Abdul                                                                                                                                                                                  Associate Director - Operations released a booklet on TPM in
                                                                                                                                                             Significant improvements, in line with the set targets, have
Wadood explained about future TPM journey and delivered            Oath taking ceremony by dignitaries and employees.                                                                                                                   Marathi.
                                                                                                                                                             been achieved and in the process of achieving these the team
key guidelines to achieve excellence. Then Managing Director
                                                                                                                                                             has practiced use of some basic TPM tools.                                 This was followed an address by Mr. Charles Pinto who brought
Mr. Rajendra Kankaria addressed key notes to motivate the
team to challenge TPM Award and expressed his confidence in
UPL team.

TPM Model machine members shared and presented their
experience and benefits enjoyed during model machine
activity. After the same function of “holi with dahihandi” is
presented to eliminate losses from the organization.

The function concluded with the vote of thanks by Mr. Atul                                                                                                   Mr. R N Bagla, Chairman-AurangabadElectricals     Mr. Deepak Chhibba, Executive Vice President-       Mr. C P Tripathi, Vice President-Works,
                                                                   Lighting lamp by Mr. Rajendra Kankaria, Managing Director, Uma Precision Ltd.,                                                               Colgate Palmolive, unveiling the TPM Policy.   Bajaj Auto Ltd and Guest of Honour, delivering
Maherotra, V.P - Finance.                                                                                                                                    and Guest of Honour, inaugurating the function.
                                                                                                                                                                                                                                                                            the keynote address

8                                                                                                                                                                                                                                                                                                       1
out how TPM is gaining increasing significance in today's          He also highlighted that the benefits of TPM are nor restricted
competitive environment with some real life examples.

Mr. Hemant Chavan, Factory Manager then shared his
                                                                   to the workplace and that TPM brings benefits to the
                                                                   practitioner even in his personal life.                                                  JK TYRE , VIKRANT PLANT
perspective behind embracing TPM while outlining some              Mr. PRC Rao, Associate Director- Operations and Ms Sarala
future milestones in the TPM journey. He exhorted the Factory      Menon, Associate Director- Customer Service and Mr. Basudeb       JK Tyre is a leading manufacturer of automotive tyres, tubes       The kick off formally began with TPM Flag hoisting by President
employees to take this initiative forward in all spheres of                                                                          and flaps of all categories viz Bias as well as Radial tyres for   (Tyre) and Safety Flag hoisting by Mr.Yoshio Egami, JIPM-S
                                                                   Roy, Associate Director – Continuous Improvement
factory activities in the right earnest and work towards                                                                             truck, Bus, Passenger, LCV, ADV & OTR, having manufacturing        Consultant and on this occasion chief guest as a sign of peace
                                                                   congratulated the Factory employees for the results achieved
becoming truly “world class” in all areas of performance.                                                                            facilities at Kankroli (Rajasthan), Banmore (MP) and Mysore        released white pigeons. The involvement of employees was
                                                                   in a short span and wished them success. Quite a few Factory
                                                                                                                                     (Karnataka).                                                       visible right from first event where the classical song was
In his captivating and powerful speech,                            employees shared their personal experiences of the TPM
                                                                                                                                                                                                        presented followed by lighting the auspicious lamp.
Mr C.P Tripathi emphasized that the mindset required for           journey and expressed commitment to continue the forward
                                                                                                                                     The Vikrant Tyre plant (VTP) started operation in 1979,
successful implementation of TPM is one that, among other          march. On his farewell visit to the Aurangabad Plant, before      presently employing 2000 manpower and a capacity to                At the very start VP (Works) Mr D Ganguly read out the blessing
things, does not “tolerate” loss of any kind. He also shared his   leaving for the USA on transfer, Mr Deepak Chhibba                produce 240 tonnes/day.                                            message of VC&MD who could not be present on the occasion
own experience of implementing TPM at Bajaj Auto Ltd.              reminisced about his experience in fostering a “multi skilled”                                                                       due to business exigencies and appreciated the role of Vikrant
                                                                   work culture at the Factory during his stint in the past.He       TPM was taken as a company mission in Dec '05 and after a          team members in Quality initiative and expressed his happiness
Mr R N Bagla, in his enlightening message laid emphasis on         complimented the factory employees in achieving what was          preparation phase of nearly six months time, formal launching      on taking a right step by VTP in embarking on journey of Total
“personal discipline” as a prerequisite for successful             once considered unattainable and motivated them by saying         of TPM Kick-off took place on 09 June '06 at Vikrant Tyre          Productive Maintenance (TPM) as this venture will enhance
implementation of TPM and shared his personal experience to        that they were well on their way to becoming world class.         Plant, Mysore.                                                     Industries competitiveness. VP (Works) explained the progress
corroborate the same while calling it the “ninth” pillar of TPM.                                                                                                                                        made in the last six months on TPM Manager Model machines
                                                                   The function ended with TPM oath and a round of the Plant.        Shri AK Bajoria, President (Tyre); and Shri GP Rao, VP(HR) were
                                                                                                                                     present from Corporate Office and demonstrated their               Mr.D Ganguli, Unit Head, explained about the VTP Mission,
                                                                                                                                     commitment toward TPM implementation.                              challenges and execution planning and shared the progress of
                                                                                                                                                                                                        TPM activities carried out on Managers Model Machines with
                                                                                                                                     Mr. L. Ramkumar President & Director, Fenner, Dr R                 respect to identification of abnormalities, counter measures,
                                                                                                                                     Mukhopadhaya, Director (R&D) & Rajiv Bhatnagar from                one point lesson, Kaizens , Why Why analysis etc.
                                                                                                                                     Corporate TPM cell, Mr.Yoshio Egami, JIPM-S Consultant;
                                                                                                                                     Mrs.Sujatha Sridhar, Japanese Interpreter; various Suppliers       The model machines selected were critical in nature and senior
                                                                                                                                     and Customers; Local administration bodies; Staff and              officers demonstrated the leadership by doing Jishu Hozen
                                                                                                                                     Workmen of the plant; Business Associates, Participants from       activities in eight machines i.e. Plant Compressor #2, 3 Roll
                                                                                                                                     Kankroli and Banmore units, Consulting firms and Vendors           Calender, Tyre Curing press, Tyre building machice, Banbury
                                                                                                                                     and team from Fenner India were also graced the event.             no.2, Zero Crown- Tyre buiding and Krupp Extruder & Skiver .

   Mr. Charles Pinto, Counselor - TPM Club India,                              Participants taking TPM Oath.                                    Progress on model machines is as follows:
               delivering his address.
                                                                                                                                                  S.No.        Description                                                      Unit           Results
                            Measure Result                                                                                                           1.        Fuguai’s Identified                                              Nos.            11112

                                  P        Production/Shift increased by 24%                                                                         2.        Fuguai’s Rectified                                               Nos.            10605

                                  Q        Packaging Material Loss reduced by 71%                                                                    3.        Activity time on Manager Model Machines                          Hours           99999
                                                                                                                                                     4.        One point lessons                                                Nos.              795
                                  C        Loss Cost/Month reduced by 47%
                                                                                                                                                     5.        Good to find points                                              Nos.              271
                                  D        Schedule Adherence is 100%
                                                                                                                                                     6.        Why-why Analysis                                                 Nos.              607
                                  S        No accidents on the Manager Model Line
                                                                                                                                                     7.        Kaizens                                                          Nos.              841
                                  M        32 Kaizens generated & implemented

2                                                                                                                                                                                                                                                                   3
Mr.VJK Nair, Advisor- VTEU, Union, shared his views on TPM
and gave a commitment on behalf of workers that there will be
                                                                   As at one hand, employees had displayed their creativity thru
                                                                   songs and explained the basic principals of TPM in a very
                                                                                                                                             Loyal Textile Mills Ltd., Kovilpatti
total participation                                                simple way by enacting a skit.                                      TPM journey commenced at Loyal Textile Mills                    cone creel changing time. There were nearly 28 Kaizens
                                                                                                                                       Ltd., Kovilpatti with TPM Deployment seminar                    presented during review of manager model machines progress
Dr.R Mukhopadhyay, Director (R&D) on this occasion,                Next event was the Kick Off special ceremony, The Dharma Doll                                                                       by various members of Manager Model Machines.
                                                                                                                                       conducted by Mr. Charles Pinto in January 2004
explained the JK Tyre Quality journey which has traveled           was shown to public & its one eye was opened on the day and
various phases since its inception and achieved remarkable         on other eye the target date of challenging TPM Excellency          and subsequent to this momentum was fuelled
results and emphasized that Quality is a never ending journey      Award was written as 2009 by Mr.D Ganguly. Mr. Y Egami on           by Mr. S.Narasimhan through his untiring efforts.               A cross functional team was constituted to remodel stores
and one should work continuously to improve all key                this occasion explained that this Dharma Doll is designed in        TPM Learning                                                    stacking system using digital codes and this project enabled to
performance parameters through Quality.                            South India and has a special feature to retain its vertical        After in-depth deliberation on various criteria for choosing    make 50% store space vacant besides minimizing retrieval time
                                                                   position, if tilted to any of the sides. Similarly, there will be   Manager Model Machines, team had decided to choose              of any given stores item from its place. On completion of this
He indicated that major challenges faced today in JK Tyre are      obstacles during TPM implementation but organisation should         "Warping & Sizing Machines"(preparatory to weaving) as          project, all the staff was happy at Stores for reducing search
equipment reliability and competence of the people. The tool       overcome as quickly like Dharma Doll.                               Manager Model Machines and commenced its activities from        time for any material and improved morale level was noticed in
to meet these challenges is TPM and Vikrant Tyre Plant will                                                                            June 2005.                                                      the Groups.
challenge PM Excellency Award instituted by JIPM-S by 2009.        Coinciding with the Foot Ball World Cup inauguration at
                                                                   Germany on 9th June'06, Egamisan Kicked off a Football from         Work place                                                      Kick Off
Members from JK Tyre VTP family presented their creation in        the stage symbolizing TPM Kick-Off at VTP.                          Prior to the commencement of TPM practices the practice of 5S   Having gained confidence in practicing TPM concepts at work
the form of song and recited the commitment song indicating                                                                            was instituted. Thereafter autonomous Maintenance Step 0-3      sites, the Manager Model Machines members expressed their
JK Tyre to achieve no.1 position globally.                         And as a declaration of resolution, TPM oath was taken by all       levels were established with the timely help of Mr.S.N TPM      desire to go in for TPM Kick Off and there were confirming Step
                                                                   members which was administered by VPW.                              Counselor. The autonomous maintenance has brought change        3 practice at Manager Model Machines.
There were short speeches made by representative of Suppliers                                                                          in mind set of permanent operators and at later part of the
                                                                                                                                                                                                       Accordingly, Kick off ceremony was held on 10th July 2006.
,i.e ,by Mr R K Dad, Sr Vice President (Projects) of M/s Hi-Tech   Unit Head reconfirmed the commitment along with Business            TPM journey, operators associated with the members of
                                                                                                                                                                                                       Preceding Kick Off, Mr.H.T.Rajan, Managing Director, TTK LIG
Carbon and representative of Customers Mr Rajesh Agarwal,          Unit heads and SSU heads. Vote of thanks was given by Mr. M         Manager Model Machines.
                                                                                                                                                                                                       Ltd. invited to witness progress made by the members of
Managing Director of M/s Cherry Agencies. Subsequently             Venkat Ramaiah, DGM –TPM.
                                                                                                                                       KAIZENS                                                         Manager Model Machines. During his inspection, he gave some
,Voice of the Human asset ,Union President Mr G Jayaramu
                                                                                                                                       KK projects were taken in the Manager Model Machine. One        of valuable suggestions for further improvements in Manager
committed for whole hearted participation from each member         The pleasant tune of Vande Matharam was played on flute by
                                                                                                                                       of the projects was to reduce set change time reduction in      Model Machines. In the afternoon, at Kick Off function, Chief
for bring the equipment conditions to the best state and           Mr. Satyanarayana to conclude the programme.
                                                                                                                                       sizing machine. Through structured approach, team was able      Guest, Mr.H.T.Rajan shared his observations with a larger
improvement productivity of the plant in all respect.
                                                                                                                                       to save average 155 minutes/day and reduction of set change     audience. Mr.Manikam Ramaswami, Chairman and Managing
                                                                   The VTP team displayed the progress done in their Model
                                                                                                                                       time has reduced by 42% (ie. from 98 minutes to 57 minutes).    Director, Loyal Textile Mills Ltd., declared TPM adoption in Loyal
On this occasion, a Special issue of Newsletter “TPM Kick          machines thru an innovative display of stalls and explained
                                                                                                                                       Additional production levels achieved on account of this        Group of companies and kicked off a foot ball as a symbolic
–Off” and a pocket booklet on TPM was released by Shri AK          Kaizens done on the machines and involvement of the team
                                                                                                                                       project was at 755 kgs/day. In the second project, fabric       gesture for TPM kick off.
Bajoria - President (Tyre).                                        members was also visible in the various Jishu Hozen related
                                                                   activities completed on their machines. The programme was           realization was improved from 95.58% to 97.23%. Third
                                                                                                                                       cross functional team focused its attention on reduction in     Mr S Narasimhan explained to audience about impending
Shri AK Bajoria also delivered a presidential Address and          evaluated as a great success by all the guests and a new
                                                                                                                                       remnant cone percentage reduction. Remnant cone                 milestones of TPM journey. TPM kick off function was
motivated the team to challenge the award much before 2009.        challenge for taking VTP to a greater height was taken by all
                                                                                                                                       percentage was reduced to 2.31% from 7.2% and thereby           concluded with sharing of TPM participative experience by
He also emphasized the importance of TPM in today's scenario       VTP family members.
                                                                                                                                       cone rewinding process was limited to half a day activity and   operators in Manager Model Machines.
and expressed his confidence in Vikrant team.
                                                                                                                                       improved morale of the work group by way of reducing run out

4                                                                                                                                                                                                                                                                     5
Mahindra & Mahindra Ltd,                                          Paranjape Autocast Pvt. Ltd.                                 Date of TPM Kick-Off function : 9th June 2006

   Zaheerabad Plant                                               Commenced its operations in 1973 at Pune.                    Delegates presents :
                                                                                                                               1.Mr. Abdul Wadood – CII
                                                                  Today, we are a group of Grey Iron and Aluminium foundries
TPM activities were started in Zaheerabad plant about a           manufacturing components by shell molding and LPDC process   2.Delegates from customers like Hero Honda Ltd.,
year and a half back. In F06, TPM drive was accelerated and       Total Manpower employed is 900.                              Bajaj Auto Ltd., Honda Motorcycles & Scooters I. Ltd.,
started taking strong roots within the plant. With this in        We have four plants in Satara District.                      Cummins India Ltd, Cummins IPO,
mind Management felt that the plant was ready for a TPM           Plant 1 : Grey Cast Iron Foundry at Satara                   Concentric Pumps ( India ) pvt ltd, KMCL ( Pune ).
Kick off ceremony to spread TPM activities plant wide. The        Plant 2 : Grey Cast Iron Foundry at Shirwal, Dist. Satara    3.Our suppliers & subcontractors.
kick off ceremony took place on 15th June '06.                    Plant 3 : LPDC Aluminium Foundry at Satara                   4.All employees.
                                                                  Plant 4 : Mechanized Grey Cast Iron Foundry at Satara
TPM Kick Off was launched by Dr. Pawan Kumar Goenka,              Manufacturing facilities are certified by BVQI
President, Automotive Sector. M/s. Rajan Wadhera, Sr. Vice
                                                                  for TS-16949 Certification
President - Manufacturing and L. P. Pereira, Sr. Vice President
Quality & Engg. also graced the occasion.
                                                                  Facilities where TPM started :
On this auspicious day Zaheerabad Plant presented to the          TPM declaration on 30th September 2005
senior management, the progress of TPM activities till date.      Plant 3 : LPDC Aluminium Foundry at Satara
There was a plant walk around by Dr. Pawan Kumar Goenka           Plant 4 : Mechanized Grey Cast Iron Foundry at Satara
to observe first hand, the progress of TPM pillar activities.     Managers Model Machine Projects :
The 12 JH stages, Kaizen activities, LCA etc. were highly
appreciated by Senior Management. Their comments gave             1. Heat Treatment Machine
further boost to the morale of employees in the plant.            2. Low Pressure Die Casting Machine No. 5
                                                                  3. HMSI Core Shooter
Dr. Pawan Kumar Goenka also inaugurated Ingenious LCA
                                                                  4. Administration Project
workshop setup in the plant and expressed great
                                                                  • Bill passing in 4 days
satisfaction in the activities being carried out.
                                                                  • Paper work reduction w.r.t. subcontractors.
During the Kick Off ceremony Mr. N.K. Shivananda – TPM            5. One project in Development
Consultant, spoke about the passion that has to be                6. One project in Mechanized Grey Cast Iron Foundry
inculcated in every employee so that every activity is taken          (One heat per hour)
as a TPM activity in order to make the plant achieve
excellence in Productivity, Quality, Cost, Delivery, Safety and
Morale (PQCDSM).

6                                                                                                                                                                                       7

Shared By: