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Implementation of TPM on Press Brake Machine

6.4 ROUTE MAP 6.4.1 Daily:

Figure 8: Route map for daily inspection

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6.4.2 Weekly

Figure 9: Route map for weekly inspection

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Implementation of TPM on Press Brake Machine

6.5 TPM KAIZEN SHEETS

Figure 10: Tpm-kaizen idea sheet 1


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Figure 11: Tpm-kaizen idea sheet 2

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Figure 12: Tpm-kaizen idea sheet 3

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Figure 13: Tpm-kaizen idea sheet 4

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6.6 OEE CALCULATION

OEE FOR THE MONTH OF APRIL Item Shift Length Short Breaks Meal Break Down Time Ideal Run Rate Total Pieces Reject Pieces Table 5: Data for the month of April Data 8hrx2shiftsx24days = 23040min. 2 @ 15 min. = 30 min. 1 @ 30 min. = 30 min. 2256 minutes 1 pieces per minute 14348 pieces 893 pieces

Planned Production Time= [Shift Length - Breaks] = [23040 - 2880]= 20160 minutes Operating Time= [Planned Production Time - Down Time] = [20160 - 2256] = 17904minutes Good Pieces= [Total Pieces - Reject Pieces] = [14348 - 893] = 13455 pieces

Availability

Operating Time / Planned Production Time 17904 minutes /20160minutes 0.89 (89%)

Performance = =

(Total Pieces / Operating Time) / Ideal Run Rate (14348 pieces /17904 minutes) / 1 pieces per minute 0.82(82%)

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Implementation of TPM on Press Brake Machine

Quality = =

Good Pieces / Total Pieces 13455 / 14348 pieces 0.93 (93%)

Availability

Operating Time / Planned Production Time 17712 minutes /20160minutes 0.87 (87%)

OEE = =

Availability x Performance x Quality 0.89 x 0.82 x 0.93 0.67 (67%)

Table 6: OEE for the month of April

THE OEE FOR THE MONTH OF APRIL WAS 67%

HENCE WE CAN SEE THERE IS A RISE IN THE OEE AFTER IMPLEMENTING TPM TECHNIQUES.

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6.7 COST ANALYSIS:


COST ANALYSIS FOR THE MONTH OF FEBRUARY:

Revenue Quoted

= Total product produced x price per piece

= 13850 x 80

= 1108000 Rupees

Actual revenue

= Total no of Quality product x price per piece

= 12890 x 80

=1031200 Rupees

Loss due to rejected

= Scraps x price per piece

= 960 x 80

= 76800 Rupees

Loss
DOWNTIME Ideal run rate Products that could have been produced during downtime Revenue that could have been generated during downtime

Due

To

Downtime
= 3960 minutes = 1 piece per minute

Downtime x Ideal run rate = 3960 X 1 = 3960 pieces

Pieces x rate per piece = 3960 X 80

=316800 Rupees

Table 7: Cost analysis for February

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Implementation of TPM on Press Brake Machine

COST ANALYSIS FOR THE MONTH OF APRIL: Revenue Quoted = Total product produced x price per piece Actual Revenue = Total no of Quality product x price per piece Loss due to rejected = Scraps x price per piece = 893 x 80 = 71440 Rupees =13455 x 80 =1076400 Rupees = 14348 x 80 = 1147840 Rupees

Loss
DOWNTIME Ideal run rate products that could have been produced during downtime revenue that could have been generated during downtime

Due

To

Downtime
= 2256 minutes = 1 piece per minute

Downtime x ideal run rate = 2256 X 1 = 2256 pieces

Pieces x rupees

= 2256 X 80

=180480 Rupees

Table 8: Cost analysis for April

A significant reduction in down time can be observed from the month of February to April.

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Conclusion
The press brake machine which did not have proper maintenance and was creating bottleneck in the production, now has higher overall equipment effectiveness. Also noticeable is the reduction of defects in the samples.

TPM has also created awareness among the operators, a sense of responsibility and also
provided a safe working environment for them. TPM has increased the availability of the machine due to good maintenance, has increased revenue for the company and hence acts as a cost saving tool.

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References
1. Implementation of TPM- Steve Borris 2. www.plant-tpm.com 3. www.tpmclubofindia.com

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