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on past 9 months data ,the plant breaks down for 180 mins daily includes not only machinery breakdown ,but also plant stoppages due to man power shortages and inefficiencies BREAKDOWN SLOWS SUBSEQUENT PRODUCTION BY ATLEAST 20% FOR AN HOUR
Frequency 45 40 35 30 25 20 15 10 5 0 Filli Fr qu Ot rs (7 c us s) ¥ ¢ ¥¡ M ¥ ¦ £¢ Im Pri t r ¥£ ¥¤¢ ¤£ v r M/c LPG M/c p w r £¥ ¥ cy ¥ ¦¥¤£ ¢¡ .
180 Mins of Daily Breakdown goes to Changeover 17 12 50 60 LPG M/c 7 26 Image Printer Filling M/c Man o er Others (7 causes) ¨§ .
LPG Filling.Changeover and Manpower Shortages : 25% of problems causing 77% of wastages . Premix Filling .
5 6344586 . The breakdowns costs the company Rs 63.5 lakhs each year (excluding oppurtunity costs) Cost Analysis (Rs) Manpower Cost Overhead Cost Material Lost Interest Cost Per Day 921 5110.875 691.2 14425.55 Total (Rs) Per Annum 276300 1533262.5 207360 4327663.
CHANGEOVER LPG Filling Machine Pre Mix Filling Machine Manpower Issues .
Changeover The average changeover time is 76 mins Changeover time can be reduced by application of SMED Standardize the changeover process Prepare a ready to use tool kit and maintain it properly in lock and key Train one more person per shift Changeover time can be reduced from 76 mins to 20 mins per shift .
23lpa PAYBACK PERIOD = 20 days .)=Rs 30000 Cost Of training additional manpower (@ 3 training sessions per person) =400 Cost Of Standardisation = 0 Potential Savings = 12/180 *63.5 lpa =4. Cost Of tool kits (2 Nos.
O Rings and seals be kept at aerosol shop itself Regular replacement of spares like 5x2 valve. Also more daily checks be included keeping data analysis done (See sheet) Spares like Festo Oil.O Rings.Implement TPM to improve machine performance The filling and LPG m/c ownership be given to operators with authority to directly contact mantainance.NRV springs based on included data analysis and after discussion with mantainace M/c overhaul of LPG m/c needs to be donw .
. Regular changeover schedule for certain spares to be done which otherwise cause huge breakdowns (See Sheet) Control Charts to be implemented on LPG and filling m/c to detect early breakdown and deviation from normality.
5% O RING NRV SPRING 8% Others 2.5% . LPG Filling M/c Percentage (Time) 17% SOLUTION GUN OVERHAUL REGULAR CHANGE (2 months) REGULAR CHANGE (3 months) Problem LPG FILLING GUN 72.
9% 20.Festo Oil Pump Overhaul.A checks A checks Regular Change .Seals.8% 12% Solution Filling Variation Crimping Head 5x2 valve. Filling Machine Problem Percentage (Breakdown Time) 60.
33 lpa to aerosol division losses are mainly in form of manpower shortages and productivity decrease due to low repeatability problems become severe in harvesting season Manpower Manpower . Manpower problems cause losses to the tune of 21.
Total 7000 6000 5000 4000 3000 2000 000 0 Manpower Not Avaliable Total © Manpower Salary Manpower Shortage Manpower New Manpower .
Manpower shortages account for about 63% of lost productivity due to manpower issues Avaliability Of Manpower accounts for 21% of lost productivity losses due to decreased productivity can be reduced if schemes like attendance bonus and productivity bonus are initiated. Non The .
000 Productivity Bonus @ 10% of losses = Rs 5600 pa This can be distributed quarterly for improved performance over and above current wages .33 lpa Loss per person = Rs 56. Current Allocated Manpower :38 Productivity Loss due to manpower shortages :21.
On an average each worker takes a 25 min break after every 2 hour Total wastage time per worker per day = 300 mins This results in decreased productivity and slowed speed of production Introduce worker facilities like drinking water and washrooms in aerosol area Implement punching system in aerosol area .
Aerosol line is run on man days wage payment method results in reduced motivation to improve productivity Contractor should be fined equal to cost of decreased productivity This Labor .