WELCOME

LDMS PROJECT:
TPM - TOTAL PRODUCTIVE MAINTENANCE

TEAM-SBU C
JAYANT S, JITENDRA B, SASI K, PRASAD K,

24-08-2022

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WELMADE LOCKING SYSTEMS PVT LTD
Contents,

• Project Scope.
• About TPM & Steps.
• Pilot machine & Current scenario.
• Abnormalities list.
• Way forward.

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 TPM A

C P

D
Project Scope:
Project Theme: Project Team: SBU - C
TPM – Total Productive Maintenance Mr. Jayant, Mr. Sasi, Mr. Prasad, Mr.
Borase,
Scope: W648 – Key ward milling. Goal:
31-Oct-2022
P  Obtain Minimum 85% OEE.
Q  Operate in a manner, so that there are no Business Benefits:
customer complaints. Production OEE Improvement to 85%,
C  Reduce the manufacturing cost by 15% Zero BAD.
D  Achieve 100% success in delivering the
goods as required by the customer.
S  Maintain an accident free environment.
M  Increase the suggestions by operators.
Develop multi-skilled and flexible workers.

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WELMADE LOCKING SYSTEMS PVT LTD
 TPM A

C P

TPM, D

 TPM (Total Productive Maintenance) is a holistic approach to equipment maintenance

to its basic condition that strives to achieve perfect production.
 Do routine Cleaning, Greasing / Oiling, Inspections, and Replacing parts.
 Objectives - “0 BAD”

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WELMADE LOCKING SYSTEMS PVT LTD
 TPM A

C P

TPM STEPS D

 TPM team formation

 Green & white tagging.
 Abnormalities MIS including Action plan, target dates, responsibilities.
 Autonomous maintenance.
 Visualization of AM check list points based on frequency.
 Machine breakdown/PM history card.
 Weekly TPM meetings.
 Standardization, WI, Sustain.

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WELMADE LOCKING SYSTEMS PVT LTD
 TPM A

C P

PILOT MACHINE FOR TPM D

 MACHINE NAME:- KEY WARD MILLING SPM

 MACHINE NO:- W-648
 CRITICALITY-HIGH

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WELMADE LOCKING SYSTEMS PVT LTD
 TPM A

C P

CURRENT SCENARIO D

 MTBF- 220.25 HRS

 MTTR-4.75 HRS
 OEE-72% (July-22)
 PPM- 3285 (July-22)

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WELMADE LOCKING SYSTEMS PVT LTD
 TPM A

C P

ABNORMALITIES LIST D

Abnormalities List - White Tags @ (Expert required to rectify)

Site Building SBU C Gemba Key Ward Milling Date
Listed By Jayant S., Prasad K.,Sasi K., Jitendra B. 16.08.2022
No. Item & Description of Abnormalities Action of Rectification Done By Done Date
1 Pneumatic cylinder sensor loose, tied with tape. New sensors to be install
2 Machine cables and pneumatic pipes tied with cable ties. Flexible pipes to be used
3 FRL not accessible to operator. FRL location to be shift so that operator can access
4 Burr curtains around cutter are wear. New burr curtains to be installed
5 Safety guard broken, tied with tape. New Safety gaurds to be replace.

Abnormalities List - Green Tags @ (Operator can rectify)

Site Building SBU A Gemba Key Ward Milling Date
Listed By Jayant S., Prasad K.,Sasi K., Jitendra B. 16.08.2022
No. Item & Description of Abnormalities Action of Rectification Done By Done Date

1 Machine burr not cleaned as per AM sheet Machine burr cleaned daily as per AM sheet

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WELMADE LOCKING SYSTEMS PVT LTD
 TPM A

C P

AUTONOMOUS MAINTENANCE D

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 TPM A

C P

D
Way forward,
S.No. What When Who Signs of Success Status
1 TPM team formation 15-08-2022 Dhananjay Project Charter Closed
2 Green & white tagging. 16-08-2022 Jitendra B Abnormalities list Closed
Abnormalities MIS including
Abnormalities
3 Action plan, target dates, 31-08-2022 Dhananjay Open
MIS
responsibilities.
Autonomous
4 Autonomous maintenance. Daily basis Operator WIP
maintenance
Visualization of AM check list
5 28-08-2022 Jayant TPM WI Open
points based on frequency
Machine breakdown/PM
6 31-08-2022 Dhananjay History Card Open
history card.
7 Weekly TPM meetings. Weekly basis Dhananjay MOM WIP
8 Standardization, WI, Sustain. 31-10-2022 Dhananjay TPM WI, SOP Open

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Thank You…

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WELMADE LOCKING SYSTEMS PVT LTD