SFL - KrishnapuramKobetsu KaizenW elcomeSundramFastenersMaduraiLim ited(SFL)Krishnapuram,SUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenSuccess through loss elimination approach of Kobetsu KaizenPresented by: S.M.Rajavikkiraman Sundram Fasteners Ltd KrishnapuramSUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenTPM implementation in SFL - KrishnapuramSpecial Award 2008 Consistency Award200 4Excellence Award199 8Part 2TPM kickoff1995 SUNFAST TPMPart 1of 8SFL - KrishnapuramKobetsu KaizenTPM Part 1 and Part 2Top ManagementPlanningFinancePersonnelGeneral AdminProductionDesign & DevelopmentMaterialsMarketingPlant 1Plant 2Plant 3TPM Part 1: Main focus on factory TPM Part 2: Company wide TPM including all functions SUNFAST TPMtCourtesy:JIPMof 8OTPM - FactorEducation & TrainiPlanned MaintenanceZero Accidents - Zero Defects - Zero Breakdowns Zero LossesKobetsu Kaizen8-pillar approach to TPM implementation in Part 1Jishu Hozen5S (Seiri Seiton Seiso Seiketsu Shitsuke)SUNFAST TPMQuality MaintenanceSFL - KrishnapuramSafety, Health & EnvironKobetsu KaizenInitial Control - Pof 8SFL - KrishnapuramKobetsu KaizenTransition from Part 1 to Part 2 Addition of new pillars OTPM - Purchase OTPM - Marketing Dividing the Initial Control P/E pillar as, Initial control - Products Initial control Equipments Categorising the pillars as, Internal focus pillars Customer focus pillarsSUNFAST TPMt of 8Education & TrainiOTPM - FactorPlanned Maintenance11-pillar 2-tier approach to TPM implementation in Part 2Hi Q Lo C Speed Customer DelightKobetsu KaizenSFL - KrishnapuramJishu HozenSafety, Health & EnvironQuality MaintenanceKobetsu KaizenCCuusstotommee rr FFooccuus eddIInnteterrnnaal l FFooccuus eddZero Accidents - Zero Defects - Zero Breakdowns Zero LossesSUNFAST TPM5S (Seiri Seiton Seiso Seiketsu Shitsuke)of 8Initial Control-EquipmeInitial Control-ProductsOTPM - MarketingOTPM - PurchaSFL - KrishnapuramKobetsu KaizenStep Change in Part 2Level of PerformanceGradual improvement (Kaizen activities)Step change (Innovative/breakthrough activities)Gradual improvement (Kaizen activities)Period of timePart 1 Part 2of 8SUNFAST TPMSFL - KrishnapuramKobetsu KaizenFocus areas for Step Change in Part 2Top 4 PillarsFocus areaOTPM-Marketing IC-Products OTPM-Factory Kobetsu Kaizen (KK)Strategies Technology Systems MethodologySUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenFocus areas for Step ChangeTop 4 PillarsFocus areaOTPM-Marketing IC-Products OTPM-Factory Kobetsu Kaizen (KK)Strategies Technology Systems MethodologySUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenSuccess through loss elimination approach of Kobetsu KaizenSUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenSuccess through Kobetsu Kaizen approachSUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenObjectives of KK pillar q Improve OEE/OPE of equipments Through reduction of time losses From 16 major losses Additional new losses q Achieve total product cost reduction Through reduction of resource losses From 16 major losses Additional new losses VA/VE improvementsSUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenObjectives of KK pillar q Improve OEE/OPE of equipments Through reduction of time losses From 16 major losses Additional new losses q Achieve total product cost reduction Through reduction of resource losses From 16 major losses Additional new losses VA/VE improvementsSUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenMethodology for total product cost reductionCost structure Loss structure Potential VA/VEEstablish relationship between 1. Costs and Losses 2. Costs and VA/VELoss-cost Relationship MatrixSUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenCost structureTotal Product CostRaw material CostConversion CostTools Sub-contract Power Freight Outward Spares Chemicals Bought out service HSD Oils and lubricants Packing Materials Variable othersEmployee CostFixed CostDiv.Heads Corp. over heads Special revenue Utilities & building Travel & conveyance Fixed othersSUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenLoss structureLosses 16 major losses Time lossesLosses affecting availability Job change time loss Breakdown loss Customer complaint loss Losses affecting performance rate Losses affecting quality rate Schedule downtime losses Management lossesNew lossesSub-contract lossResource lossesInventory loss Energy losses Tool loss Yield loss Bought out service loss Premium freight lossSUNFAST TPMEliminateof 8SFL - KrishnapuramCombineKobetsu KaizenPotential VA/VE improvementsReduceVA/VE ImprovementsSimplifyDesign VA/V ERaw Material ToolsProcess VA/V EMachine Output VA/VESpeed-upLabour Productivity VA/VELunch Time Style Running Automation Single Piece Flow LinesCycle Time Reduction Multi Cavity Enhance equipment capacityLunch Time RunningSUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenLoss-cost relationship matrixRelationship Rating Scale : 1 = Weak , 5 = StrongSUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenMethodology for cost reductionLoss-cost Relationship MatrixEvaluation of loss-cost values and fixing targets for Loss reductions and VA/VE improvementsLoss reductions and VA/VE improvements targetSUNFAST TPM20 of 8SFL - KrishnapuramKobetsu KaizenLoss-cost evaluation and setting targetsLossesYield LossR s./M T BM T arget Sav ings BM T arget 18% 8%VA/VE improvementsJ/C Loss275 mts. 75 mts.Tool Loss20% 5%Energy Loss250 KWh/M T 100 KWh/M TTool VA/VE490 Rs/MT 1097 Rs/MTEnergy VA/VE80 Rs/M T 250 Rs/MTM/C Labour Output Productivity VA/VE VA/VE412 Rs/M T 1238 Rs/M T 83 Rs/M T 304 Rs/MTMajor CostRM cost Tool cost Energy cost Fixed cost Employee cost38,919 3,918 3,949 15,877 7,60029,189 2,351 2,947 9,609 6,0809,730 1,567 1,002 6,268 1,5205 1 1 1 11 5 1 1 11 1 5 1 11 2 1 3 11 4 1 1 11 1 3 1 11 1 2 4 11 1 1 1 5Relationship Rating Scale : 1 = Weak , 5 = StrongSUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenYield loss (loss no. 16) reductionSUNFAST TPMof 8SFL - KrishnapuramMTKobetsu KaizenYield loss elements250200Selected for further analysis150100500Process scrap 196Defect Loss 38Inventory Loss 21Setting Scrap 17Assorted PS 10En bit los 10Testing Scrap 8MTSUNFAST TPMof 8SFL - KrishnapuramMTKobetsu KaizenYield loss elements14063%12010037%806040200 MTNut Process scrap 120Bolt Proces scrap 76SUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenMethodology for process scrap reductionProcess scrap reductionNutBolt/ScrewsSlugTapping swarfMachining BurrTrim BurrGrinding swarfReduce slug thickness Piercing in forgingBurrless TappingForge to final shape Reduce Machining stockBurrless forgingReduce Grinding stockReduce Face machining Reduce Bore machiningSUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenProcess scrap reduction in nutsKaizen implementation matrixElements I Reduce Slug Reduce Face machining Reduce bore machining Total I - Identified C - Completed 45 7 52 Slug C 34 3 37 Make to net shape I 10 18 28 C 4 12 16 111 70 Make to near shape I 12 19 31 C 5 12 17SUNFAST TPMof 8SFL - KrishnapuramSample 25.0 Kaizen mmAFTER(Yield loss)Kobetsu KaizenProcess scrap reduction in nuts25.0 mm EFOR B EYield = 79%Yield = 89.2%RM wt. 96.0 gmsRM wt.85.0 gmsNew spring loaded die26%SUNFAST TPMof 8SFL - Krishnapuram Process scrap reduction - Nut%29 1998-99 1999-00 27 2000-01 2001-02 25 2002-03 2003-04 23 2004-05 21 2005-06 2006-07 19 2007-08 2008-09 - I 2008-0917 II Yield Loss% 26 25.2 15 24.8 24.4 25 23 22.6 21.8 21.2 SUNFAST TPM 22 19 Tgt.Kobetsu Kaizen19%Betterof 8SFL - KrishnapuramKobetsu KaizenProcess scrap reduction in boltsKaizen implementation matrix16Elements I Eliminate Trim burr Reduce OD grinding Reduce collar machining Total I - Identified C - CompletedFormed version C 32 32Make to net shape I 15 13 28 124 75 C 8 5 13Make to near shape I 26 22 48 C 16 14 3048 4816.8% SUNFAST TPMof 8SFL - Krishnapuram55% Reduction Kobetsu Kaizen Process scrap reduction - Bolt8%Better%19 1998-99 1999-00 17 2000-01 2001-02 15 2002-03 2003-04 13 2004-05 2005-06 11 2006-07 2007-08 9 2008-09 - I 2008-09 - II Yield 7 Loss% 16.8 16.4 15.8 15.5 15.1 14.5 13.2 11.5 10.4 9.5 8 Tgt. 5SUNFAST TPM 17.8%16.845%of 8ReductionSFL - Krishnapuram Kobetsu Kaizen 1998-99 1999-00 Total yield loss reduction Krishnapuram plant 2000-012001-02 2002-03 % 2003-04 20 2004-05 2005-06 2006-07 18 2007-08 2008-09-I 16 2008-09-II Yie ld Loss% 17.8 14 16.1 12 15.8 14.9 14.5 1069.7%Better1713 1211.58 10.4 6 9.7 Tgt.17.84 20SUNFAST TPM8of 8SFL - Krishnapuram Kobetsu29189 Kaizen 38918 Resultant RM cost reduction Krishnapuram plantRs./MT389183844038012375863698035840349803401233856329883158639000Better3700019% Reduction350003300031000290002700025000Cost Tgt.1998-991999-002000-012001-022002-032003-042004-052005-062006-072007-082008-09 - I 2008-09 - IISUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenTool VA/VE improvementsSUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenMethodology for Tool VA/VE improvementsTool VA/VE improvementsDesign improvement Identify high consumption / value toolsTool life improvement Using higher grade material for tool Improved surface coating for toolRe-cyclingTool Manufacturing improvement Manufacturing cycle time reductionAnalysi sUsing low cost materialIdentify design weaknessSubstitute of low cost material in non working areaOptimize tool designImproving the surface finish by changing process sequenceSUNFAST TPMof 8SFL - KrishnapuramCOST Rs./MKobetsu KaizenTool cost element-wise1,4001,200Selected for further analysis1,0008006004002000 Rs./MTST EL TO LS E O 1,250CA BI DES R 94 0ROLLI NG DIES 78 6TA PS 58 7OTHER S 355SUNFAST TPMof 8SFL - KrishnapuramCOST Rs./MKobetsu KaizenTool cost element-wise350300250200150100500 Piercing Pin T rim dies Heading Insert Rs./MT 305 245 205Nut forming insert 155PunchesDiesOT HERS15014050SUNFAST TPMof 8SFL - KrishnapuramKobetsu Kaizen Kaizen implementation matrixTool manufacturing I C 9 4 2 15 I 18 6 8 4 23 10 34 224 146 11 Design C 8 3 6 17 48 4 55 167 34 3 33 114 Recycling I 12 48 C 8 36Tool VA/VE improvements Steel toolsThemePiercing Pin Trim Dies Heading Inserts Nut Forming Dies Bolt Forming Dies Punches Common tools Total I - Identified C - CompletedSUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenTool VA/VE improvements Piercing pinSample Kaizen Split designPhase 1 - ImprovementSplit design with common material (HSS)Phase 2 - Improvement Split design with LoC materialSUNFAST TPMof 8SFL - KrishnapuramLength optimizationNo s 2 50 00 2 00 00 150 00Kobetsu KaizenTool VA/VE improvements Piercing pinOptimum length: 1.1D to 1.3DDFailure mode: Buckling Failure mode: Breakage100 00 50 00 0 1.6D 1.5D 1.4D 1.3D 1.2D 1.1D 1D 0.9D 0 .8D 0.7DLLengthResult : Tool cost savings up to Rs 1.2 million / Year ( 3.5 million yen/ Year).SUNFAST TPM39 of 8SFL - KrishnapuramKobetsu Kaizen Kaizen implementation matrixTheme Tool manufacturing I C 18 2 20 23 4 27 Design I 34 6 7 10 57 354 262 C 24 6 4 5 39 Recycling I 167 48 55 270 C 132 33 38 203Tool VA/VE improvements All ToolsSteel tools Carbides Rolling Dies Taps Other tools Total I - Identified C - CompletedSUNFAST TPMof 8SFL - Krishnapuram Kobetsu Kaizen Cost savings through Tool VA/VE improvementsRs./MT12001000Better92880060089% Improvement 490400 1998-99 1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 09Cost / MT Target 490 490 520 590 610 670 697 720 786 840 8702008-09- 2008I 928 1097 IISUNFAST TPMof 83918 39183840375036103560342033153150301028502480 2351SFL - Krishnapuram Kobetsu Kaizen Resultant tool cost reduction Krishnapuram plantRs./MT4500 4000 3500 3000 2500 2000 1500 1000 500 0 1998-99 1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 Cost / MT Target 2008-09- 2008-09I II Better34% ReductionSUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenLabour productivity VA/VE improvementsSUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenLabour productivity VA/VE improvements methodologyLabour productivity VA/VE ImprovementLunch time style runningCoupling of machinesAutomationSingle piece flow linesSUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenLunch Time Style Running (LTSR)An idea to increase labour productivity Uses multi-machine operation Single-piece flow conveyors and coupling of machines Maximizes man-machine engagement Layout changes Focuses on line organization lossSUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenMethodology for Lunch Time STYLE RunningLunch Time Style RunningTPM Part - 2Perfect CellMulti Line OperationInformatio n SystemSupport TeamPerfect LinesTPM Part - 1Perfect Machines Coupling of MachinesZero 1A/1BZero DefectsZero Minor StopsSUNFAST TPMof 8SFL - Krishnapuram Journey to Lunch Time Style Running PRE-TPMLUNCH TIME STOPPINGKobetsu KaizenTPM Part 1LUNCH TIME RUNNINGTPM Part 2LUNCH TIME STYLE RUNNING6 Machines 6 Operators Lunch Time stop Machine concept3 Lines 3 Operators Regular : 3 Op & Lunch Time :1 Op. Line concept1 Cell 1 Operator Regular, Lunch Time : 1 Op. Cell conceptSUNFAST TPMof 8SFL - Krishnapuram F FORGING MACHINE RKobetsu KaizenROLLING MACHINE OPERATORSUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenProblem / present statusWe have 3 lines of forging and rolling which are coupled Each line has got a dedicated operator Labour productivity is lowRolling machineOperator 3Operator 2Operator 1Forging machineLine 3Line 2Line 1SUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenCountermeasuresEliminate loading pits, output carrying conveyors and vibratory feeders Replace bulk feeding conveyors to Single-piece flow conveyors Re-layout to minimize operator movement Release other two operators for support / kaizen team Introduce information system between operator and support / kaizen teamSUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenLunch Time Style RunningSample Kaizen 84S1, 84S2 and 84S 3BEFORE LAYOUT MODIFIED LAYOUTOperator 3Operator 2Operator 1Operator 1Line 3Line 2Line 1SUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenLunch Time Style RunningResponsibilities for Operator and Support teamOPERATOR RESPONSIBLE FOR ALL ACTIVITIES DONE ON ROUTINE BASIS SUPPORT TEAM RESPONSIBLE FOR EXTERNAL AND SPECIAL ACTIVITIESSUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenInformation systemLTSR - Information systemSupport required from Supervisor/Manager Support required from Kaizen Team Machine is in RunningAudioLight Signal with AlarmSUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenResultLabour productivity index800 639600400213 2001000 IndexPre-TPM 100TPM Part 1 213TPM Part 2 639SUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenBenefitsSUNFAST TPMof 8SFL - Krishnapuram Cost savings through labour productivity VA/VE improvementsRs./MTKobetsu KaizenBetter350 300 250 200 150 100 50 0 1998-99 1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 Cost / MT Target 83 83 92 102 108 118 126 132 138 145 168243260% 832008-09- 200809- II I 243 304SUNFAST TPM17 % Reductionof 8SFL - Krishnapuram Kobetsu Kaizen Resultant employee cost reduction Krishnapuram plant1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 T RS/M 8000 2007-08 2008-09 - I 2008-09 - II Cost 7600 7500 7520 7410 7205 7180 7000 6950 6770 6620 6520 6500 6490 6320 Tgt. 7600 6000Better55006080 SUNFAST TPMof 8SFL - Krishnapuram Kobetsu Kaizen Total product cost reduction Krishnapuram plant10018% 27% 30%80 % 601004082 73 70200Product cos t %BM (1998-99) 100Cons is te ncy (2004-05) 82Curre nt (2008-09) 73Target 70Against the target cost reduction of 30%, we achieved 27% so far.SUNFAST TPMof 8SFL - KrishnapuramKobetsu KaizenTo Sum upTPMPart 2It is wider!TPMPart 1SUNFAST TPMIt is higher!! It is much bigger!!!of 8SFL - KrishnapuramKobetsu KaizenThank YouSUNFAST TPMof 8