IMPROVING OVERALL

EFFICIENCY
OF THE CUTTING MACHINES BY
IMPLEMENTATION OF PILLARS
OF TPM .
 IMPROVING OVERALL EFFICIENCY OF THE
CUTTING MACHINES BY IMPLEMENTATION OF
PILLARS OF TPM

 PREPARED BY


 Name of the students

q Yashraj.V.Rane.
q Harshad.V.Suryawanshi.
q Kalpesh.D.Khochare.
q Amol.P.Shetke.
q Dhiraj.B.Waghmare.

Pillars of TPM
 TPM Pillars To
Implement
PILLAR 1 - JISHU HOZEN (Autonomous maintenance):
This pillar is geared towards developing operators to be able to take care of small maintenance
tasks, thus freeing up the skilled maintenance people to spend time on more value added activity
and technical repairs. The operators are responsible for upkeep of their equipment to prevent it
from deteriorating.

PILLAR 2 – KOBETSU KAIZEN:

"Kai" means change, and "Zen" means good (for the better). Basically kaizen is for small
improvements, but carried out on a continual basis and involve all people in the organization.
Kaizen is opposite to big spectacular innovations. Kaizen requires no or little investment. The
principle behind is that "a very large number of small improvements are move effective in an
organizational environment than a few improvements of large value. This pillar is aimed at
reducing losses in the workplace that affect our efficiencies. By using a detailed and thorough
procedure we eliminate losses in a systematic method using various Kaizen tools. These activities
are not limited to production areas and can be implemented in administrative areas as well.
Why Kobetsu Kiazen?

1. Easy to implement.
2. It can be more cost effective compared to other
three processes.
3. Everyone is involved during KK activity i.e. from
manager to shop floor worker
So that every operator gets the feel of experiment
4. More operators friendly.
5. It can be done with less cost.
Why Jishu Hozen?

1.Easy to implement.
2.Uninterrupted operation of equipments.
3.Flexible operators to operate and maintain other
equipments.
4.Eliminating the defects at source through active
employee participation.
Behringer Band Saw
Cutting M/C Losses
SR.NO. ACTIVITY TIME in min %
1. Setting if JOB 115 19.79
2. Measurement 83 14.28
3. Operator non 35 4.30
4. availability
Crane waiting time 15 2.58
5. M/C down time 313 53.87
6. Tool changing time 30 5.16
TOTAL 581 100
Behringer Band Saw
Cutting M/C Losses
Three Major Losses
in Behringer:-
1.
Ø M/C Down Time.
Ø Setting Time.
Ø Measurement.
1. M/C Down Time


 REASON


Ø Maintenance
Ø


 SOLUTION


Ø Preventive Maintenance of M/C to be done on

time to avoid maintenance while M/C is in
production.


2.Setting time

 REASON
Ø Fatigue to Operator in Setting the Job.
Ø
Ø
Ø
Ø
Ø


 SOLUTION
Ø Sensors are to be employed on machine for
measurement purpose.
3. Measurement

 REASON
Ø Presently measurement is done manually by
operator.
Ø New measurement type equipment must be
procured to minimize measurement time.
Ø
Ø
Ø
Ø

 SOLUTION
Ø Sensors (stops)assembly has to be done near
to the machine blade so measurement
CNC Suag Cutting M/C
Losses
SR.NO. ACTIVITY TIME in %
1. Scheduled/Planned Stoppages min
698 49.75
2. Setting Time 17 1.22
3. Start-up Losses[mock-up] 288 20.52
4. Minor Stoppage[Time Loss] 20 1.42
5. Non Availability of Material 340 24.24
6. Non Availability of Operator 40 2.85
TOTAL 1403 100
CNC Suag Cutting M/C
Losses
Three Major Losses in
CNC Suag:-
ØScheduled/Planned Stoppages.
ØNon Availability of Material.
ØStart up Loss[mock-up].

Scheduled/Planned
Stoppages
 REASON
Ø Loading Time Of Plate Is Too High.
Ø Time consumed for Setting the Job Plate.
Ø
Ø
Ø
Ø


 SOLUTIONS
Ø Loading Time Should Be Minimized By Offline
Setting Of Plate.
Ø Special fixture to be Designed for Quick Setting of
Job Plate.

Non Availability of Material

REASON

Ø Improper & Unplanned Stacking of Plates.


SOLUTIONS

Ø Proper stacking of plates as per priority.
Ø Proper proactive planning to feed the m/c
as per plan.

Start up Loss[mock-up]
 REASON
Ø No cleaning before Operator reports the
machine.
Ø Major time consumed in Test Run.
Ø
Ø
Ø
Ø


 SOLUTIONS
Ø Special Cleaning staff to be provided for
cleaning of the m/c before operator
reports on the m/c during each shift.
Ø Special Fixture to be made to avoid Test Run.
Design probable solution
for Behringer Band Saw
Cutting M/C
Actual implementation
of scale
Design probable solution
for CNC (Suag) Saw
Cutting M/C
Actual Positioning Of
Plate For Reducing time
For Transportation
RESULTS BEFORE
IMPLEMENTATION FOR BEHRINGER
BANDSAW CUTTING MACHINE.
DATE OF PERFORMANCE MEASUREMENT TIME
4/9/2009 20
11/9/2010 30
RESULTS AFTER IMPLEMENTATION
FOR BEHRINGER BANDSAW
CUTTING MACHINE.
DATE OF PERFORMANCE MEASUREMENT TIME
22/04/2010 15
23/04/2010 24
RESULTS BEFORE
IMPLEMENTATION FOR CNC GAS
CUTTING MACHINE - SUAG.
DATE OF PERFORMANCE AVAILABILITY OF MATERIAL
11/9/2009 30
25/09/2009 20
RESULTS AFTER IMPLEMENTATION
FOR CNC GAS CUTTING MACHINE -
SUAG.
DATE OF PERFORMANCE AVAILABILITY OF MATERIAL
22/04/2010 12
23/04/2010 15
CONCLUSION

 O. E. E. IMPROVED FOR BEHRINGER

BANDSAW CUTTING MACHINE:-
DATE Before - 04 / 09 / 2009 Before - 11 / 9 / 2009
After - 22 / 04 / 2010 After - 23 / 04 / 2010
BEFORE O.E.E. 90.34 48.86

AFTER O.E.E. 92.30 60.87

FROM ABOVE RESULTS IT CAN BE SEEN THAT O.E.E. HAS BEEN IMPROVED BY
ALMOST 3% TO 15% AFTER THE IMPLEMENTATION OF TPM.
CONCLUSION

 O. E. E. IMPROVED FOR CNC GAS

CUTTING MACHINE CUTTING
MACHINE - SUAG:-
DATE Before - 11 / 09 / 2009 Before - 25 / 9 / 2009
After - 22 / 04 / 2010 After - 23 / 04 / 2010
BEFORE O.E.E. 84.1 78.3

AFTER O.E.E. 91.3 83

FROM ABOVE RESULTS IT CAN BE SEEN THAT O.E.E. HAS BEEN IMPROVED BY
ALMOST 3% TO 7% AFTER THE IMPLEMENTATION OF TPM.
THANK YOU ….