Ashok Iron Group - TPM 2008-09

MODEL MACHINE RED TAG RAGISTER - Summery

Tag category- Responsibilty -
Sr.No. Date /Shift TAG Number Tag description - Abnormality Action for Abnormality Status of the Action Remarks
Red/White Maint/Prodn
Ashok Iron Group - TPM 2008-09 Month :-
KAIZEN RAGISTER - Summery
Best Five Amount Gift Item
Sr.No. Date Kaizen Number Kaizen Idea Operator Name Dept./Location Remarks
kaizens allotted issued

Total
Selection committee :- Comments

Unit TPM Unit QA Unit MAINT. Unit HR Unit HEAD Corp-TPM SBU
Ashok Iron Group - TPM 2008-09 Month :-
SUGGESTION RAGISTER - Summery
Best Five Amount Gift Item
Sr.No. Date Suggestion Number Suggestion Operator Name Dept./Location Remarks
Suggestions allotted issued

Total
Selection committee :- 1) Number kaizens collected

Unit TPM Unit QA Unit MAINT. Unit HR Unit HEAD Corp-TPM SBU
Ashok Iron Group TPM-2008-09
MODEL MACHINE - CHECK LIST SHEET
Name of the Team Area : PLANT ----------

Name of the Auditor : L.A.Balram / S.S.Naik / Naveen kumar/ Sridhar

NAME O
Sl no. Check Points
1

01 Machine Identification in Zone

02 Machine Board display

03 Model machine Check list display

04 Initial Cleaning

05 Tags Putting - Red / White

06 Tags Removing - Red / White

07 Results Monitoring Board - TPM Board

a) Zero Accidents - Trend

b) Zero Breakdown - Trend

c) OEE - Trend

d) Qty - Item wise trend

e) Zero Rejection - Internal Rejection - Trend

- Customer Complaints - Trend

f) Kaizen / Suggestions - Qty Trend

- Before / After Photos

& others as per TPM Board requiremnt

08 Layout of the Machine

09 Model Machine team display

10 Cleaning Standards (JH3)

11 Label / Colour Identification on the Machine Parts

12 Zero Job on the floor around the Machine

TOTAL points
TOTAL score in %
EVALUATION CRITERIA
2 Marks - Almost Zero Implementation
4 Marks - Implementation Started
6 Marks - Partial Implementation
8 Marks - Full Implementation
10 Marks - Very Effective Implementation
T SHEET
Name of the Auditee : Unit Head / TPM leader / HR head
Target : Average of Model Machine 75%
(points will be converted to percentage)

NAME OF MODEL MACHINES

2 3 4 5
Ashok Iron Group - TPM 2008-09

OPL - One Point Lesson

OPL No.
Theme

Date of
Preparation
Classification

Basic Knowledge Prepared By

Improvement Cases
Division
Trouble Cases

1. What Condition is Mistake has happened ?

2. Reason for Mistake

3.What happens if Continuously used without correcting Mistake ?

4. Troubleshooting
Actual Results
Date Executed

Teacher

Student
ed By

on
Ashok Iron Group TPM 2008-09
HOUSE KEEPING (1S&2S )– CHECK LIST SHEET
Name of the Team Area : Plant ---------------

Name of the Auditor : L.A.Balram / S.S.Naik / Naveen kumar/ Sridhar

Sl Audit Item 2 S : Systematic Arrangement

No Check Points 1
01 Floors, Walls, 1. Storage positions are all fixed and have an address
Windows and Ceilings 2. All aisles have neat white dividing lines
3. Windows and walls are spotless. No posters are
put on the walls except on designated places

02 Machine and 1. The layout is designed to match the process flow

Auxiliary 2. A pleasant work environment
Equipment
03 Control Panels, Operation There are no tangled wires and where wires are going
Panels, Power Lines, can be seen at a glance
Pipes
04 Tools, Measuring 1. Storage according to shape
Instruments , Molds etc. 2. All tools can be retrieved in 30 seconds.
4. Measuring instruments-

05 Products, WIP, Materials, 1. Storage is fixed and standards established for

Defective Items, quantities in store: Standards are adhered
Subsidiary Materials 2. There are signs and labels to control WIP

06 Workbenches, Shelves, 1. Usage is clarified and displayed

Carts, Toolboxes, 2. Actual items match labeling
Cleaning Equipment, 3. Unnecessary items have indication of deadline for
Personal Belongings, elimination
Subsidiary Materials,
Unnecessary Items
07 Staff Everyone is interested in fixing storage positions
and ensuring a smooth flow for the extraction and
return of tools to improve productivity

Total : 2S Shop Floor

S.NO. CHECKING ITEM CHECKING ITEM 2S : EVALUATION CRITERIA
1

Labelling of lockers and

01 Lockers Storage labels equipments allows immediate
identification.
 Labels for
02 Desks documents & Everything is clearly identified
equipments

storage is designed for ease for

03 Visual control Ease of use
use

Everything is stored in a fixed

04 Standards for disposal Orderly storage
place

Aisles and All dividing lines and bulletin

05 Exhibits
display areas boards are clearly indicated

Total : 2S office
NOTE : Overall Unit score will be through mail.

1
S

2S chart -
c
h
a
r
t
-
S
h
o
p
f
l
o
o
r

8012
6734

3
 8012
6734

2S chart
1S
ch
ar
t
-
O
f
ic
e

8 2

7 0 3

6 4

3
K LIST SHEET
Date :

Name of the Auditee : Unit Head / TPM leader / HR head

Zones
2 3 4 5 6 7 8 9 10 11 12 13 14 15

Zones

2 3 4 5 6 7 8 9 10 11 12 13 14 15
2S chart - Shop floor

60
40
20
0

3 2
 40
20
0

3 2

2S chart - Office

60
40
20
0

3 2
AIG Model Machine Machine layout
Dust RW/Rejected
Chips trolley material
collect
or

Cont Tool
rol Machine /kit
pane stand
l

Opr
IN PUT Inspection OUT PUT
material stand material
Find attachement
 Kaizen Sheet
Pillar KK JH PM QM IC E&T OTPM SH&E
Ashok Iron Works Loss/Step No.
Result Area P Q C D S M
Kaizen Kaizen
Theme Idea
Problem / Present Status: Countermeasure:

(Before) (After)

Analysis: Results:

Before
Area/Model Kaizen S.No.
Operation Start Date
Machine Finish Date
BM
Target
Team Members:

Benefits:

Standards/Documents Issued/Updated
JH Standards OPL
PM Standards OQA Std.
Work Instruction Gauges
Part Drawing FQA Std.
Process Sheet
Tool Drawings

Horizontal Deployment Details:

After
Ashok Iron Group
TPM BOARD - MODEL MACHINE Plant- -------------

Model machine Team Structure (1) Trend graph OEE - Monthly Trend Graph - (1) One Point Lesson sheets
(2) Productivity - (1) Customer (2) MP sheet
Monthly complaints- Nos., Monthly
(2) Internal rejection - Percentage,
Monthly
(3) Cp, Cpk

Check Sheet - (1) Production - Day wise Trend Trend Graph Trend Graph -
(1) Model machine graph (1) RW - Qty,
Monthly (1) Accidents - Monthly
(2) Zone (2) Salvage - Qty,
Monthly
(3)Pareto of Defects - Monthly

Tag Trend Graph - (1) Trend Graph - Monthly Break Trend graph - Cost Trend Graph ;-
(1) Tag put down Hours (1) (1) Delivery Adherence - Monthly
(2) Tag removed (2) Trend Graph - Consumables cost - Monthly (2) Schedule
Monthly Occurrence (2) Adherence- Monthly
Power cost -Monthly
(3) Maintainance
cost- Monthly

Trend Graph - Before / After Photos for Trend Graph - Losses 1) Machine layout
(1) Suggestion (1) kaizen (1) No load - Hrs,
(2) Kaizen Monthly
(2) Suggestion (2) No power - Hrs, monthly
(3)House keeping ( If (3) Set up change time - Hrs, Monthly
availability)

Tag Register Spare Tags - Action

Red/White Completed
Tags
Tags