TPM

KK PILLAR

KK PILLAR

TRAINING MODULE

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 TPM
KK PILLAR Outline

• Target Achievements
• OEE – Significance & Formula
• Loss – Definition
• Types Of Losses
• Examples Of Losses
• Losses Segregation
• OEE Calculation
• Loss Reduction Strategy
• Suggestions

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KK PILLAR
Target Achievements

• What is Target??
• It is the expectations that fulfils the Business Goals

• What all things done to achieve the given targets?

1. Production planning & control. (PPC)
• If the targets are not achieved according to plan?
1. Increase Overtime
2. Add shifts
3. Purchase new equipment
• Increasing overtime and adding shifts increases production cost and the net profit
on these days is almost equal to zero.
• Payback period of new equipment decides its feasibility

• Why targets don’t get achieved in decided period of time??

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 TPM
KK PILLAR Target Achievements

• What else can be done to achieve the targets??

1. Increase Equipment availability
2. Minimize setup & adjustment and tool change time
3. Improve operator efficiency
4. Lower overall down time

• Improving all the above parameters ultimately increases the productivity

• How to monitor these improvement? or How to monitor

these improvements in measurable terms??

• The term OEE is used to monitor these improvements.

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KK PILLAR OEE

• OEE –
OEE is nothing but Overall Equipment Efficiency.
It is defined as an effective tool to benchmark, analyze and monitor the production
process.
OEE is developed in mid 1990’s
OEE has been broken down in to three different parameters.
1. Availability
2. Performance
3. Quality

OEE = Availability x Performance x Quality

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KK PILLAR OEE

• Availability –
Percentage of the actual amount of production time the machine is running
(uptime) to the production time (Net Available Time) the machine is
available

–
• Availability = ( )x100

• Performance –
Percentage of production rate of the machine to total parts produced on the
machine

Performance =

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 TPM
KK PILLAR OEE

• Quality –
Percentage of ok parts out of the total parts produced on the machine
Ok Production
Quality = Total day production
100

• Availability and performance of the machine and Quality of the product ultimately
depends on the losses.

• OEE varies with A, P and Q

• So ultimately OEE is related to all the LOSSES and varies in

accordance with them.

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 TPM
KK PILLAR WHAT IS LOSS ??

• Definition of Loss –
In day to day life anything that directly or indirectly affects your monitory value is
a loss
Same principle applies to our industry.
Our monitory value or sale depends upon the production and anything that is an
obstacle in the process of production is a loss.
e.g. Die grinding, Lack of man-power, unskilled operator, no material, waiting for
dies
Loss is inversely proportional to our sale value and it ultimately affects our
company growth.

Company Personal
Increase Reduction in
Growth Growth
in Loss sale-value
??? ??

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KK PILLAR

16 – Losses

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 TPM
KK PILLAR Types Of Losses

16 Major Losses are :- 1) Equipment failure loss

2) Setup loss
3) Tool change loss
4) Startup loss
5) Minor stoppage and idling loss
6) Speed loss
7) Defects and rework loss
8) Shutdown loss
9) Management loss
10) Operating motion loss
11) Line organisation loss
12) Logistic loss
13) Measurement and adjustment loss
14) Yield loss
15) Energy loss
16) Die and tool loss 10
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KK PILLAR Loss Definitions

• Equipment Failure Loss –

Failure of machine during production process or Production process stoppage
due to stoppage of any of the machines is equipment failure loss
e.g. Bottom ejection not working, Robot error, Press O/R Issue
It is a loss with major contribution in production process.
It reduces sale value and also increases repair and maintenance cost.
Equipment failure loss

Due to weak JH 2. Due to weak PM

(Poor operator knowledge and skill) (Non-adherence to PM
check sheets and PM calendars)

Equipment failure Availability Productivity

Loss of M/C

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 TPM
KK PILLAR Loss Definitions

• Set up & Adjustment Loss –

The time lost during changeover from one product to another product and then the
adjustment time to first OK piece.
Time lost in removing the dies of previous run to getting the first ok piece of the
next run is nothing but set up & adjustment time.
Time study is taken to find out different bottlenecks in set up process and actions
are taken on the same

• Tool change loss –

Time lost in changing the tools i.e. single die, trim or padding die or punch, heat
code change
Tool handling & Tool change data monitoring are the major bottlenecks. Tool
life improvement is also a major concern.

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 TPM
KK PILLAR Loss Definitions

• Start up Loss-
Delay in starting the equipment due to condition like temperature built up.
Time required to achieve the required die temperature is nothing but the start up
loss.
Start up loss can never be completely eliminated but can be reduced by
considering factors like die heating media (heating net design) or flame.
• Minor stoppages –
Stoppage of the equipment due to minor snag and restoring the condition
Time spent in tightening or replacing die or tooling bolts, any packing related
issue or any kind of equipment failure loss occurred due to weak JH is recorded under
this loss
In order to reduce the loss, adherence to all 1-s, 2-s activities and JH related
activities should be 100%

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 TPM
KK PILLAR Loss Definitions

• Speed Loss –
Loss due to difference between actual speed and standard speed
Time lag between the actual cycle time and standard cycle time is nothing but
speed loss
Operator skill enhancement and fatigue reduction are the concerned points to
reduce this loss.

Speed Loss (Hrs) =
• Defect Loss –
Indirect un-availability of machine due to production of defective parts
∗
Defect Loss (Hrs) =
Rejection = Process rejection (at forging stage)

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 TPM
KK PILLAR Loss Definitions

• Shutdown Loss –
All in-direct value adding activities to production & no plan situations are
recorded under this loss.
e.g. JH & TPM circle related activities
All the value adding activities & no plan situations are recorded under this loss so
this loss doesn’t get added in total down time while calculating OEE
• Management Loss –
Stoppage of machine due to want of material from feeder shop, no power or no
manpower et c.
• Motion Loss –
Loss occurred due to violation of motion economy is nothing but the motion loss.
Motion Economy???

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KK PILLAR

• Line Organization Loss –

Time lost in waiting in multi machines processing due to unequal distribution of
work content.
e.g. Un-availability of billets due to cycle time difference in cutting & forging
process
• Logistic Loss –
Time loss due to stoppage of machine due to logistic reasons like internal material
movement, delay in issue to line
e.g. No pallets, forklift not available or crane not available etc.
• Measure & Adjustment Loss –
Time loss due to equipment stoppage by operator for frequent inspection of parts
and to make any adjustment if necessary
Due to different quality issues, line has been frequently stopped to make
corrections like die grinding.

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KK PILLAR Loss Definitions

• Yield Loss Cost –

Weight difference between raw material and product
There are three different terminologies related weight
1. Cut Weight
2. Gross Weight
3. Actual Weight
• Cut Weight –
Weight of the cut billet measured immediately after cutting (Monitoring is done
Hourly and recording is done in hourly inspection report)
• Gross Weight –
Billet Weight + End Piece Weight + Trim Cut + Burr (Mentioned in stock size)
• Actual Weight –
The weight of the billet that is predefined in terms of tolerance limits of the
diameter of the billet (Mentioned in the stock size)

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 TPM
KK PILLAR Loss Definitions

• Energy Loss –
Input energy that cannot be effectively used for processing.
e.g. Unwanted running of equipment like man cooler, conveyers.

• Die/Jig/Tool Loss –
Extra expenses needed for replacing die, tools, jig which are worn out or broken
over long services.
e.g. die grinding, crack die repair, ejection pin correction etc

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KK PILLAR

16 Major Losses--Category wise

A) 7 Major losses which obstruct OEE

(1 to 7)
1. Equipment failure loss
2. Setup loss
3. Tool change loss
4. Startup loss
5. Minor stoppage and idling loss
6. Speed loss
7. Defects and rework loss

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KK PILLAR

16 Major Losses--Category wise

B) Loss which affects the equipment loading time

8. Shutdown loss

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KK PILLAR

16 Major Losses--Category wise

C) 5 Major losses preventing efficiency of manpower

(9 to 13)
9. Management loss
10. Operating motion loss
11. Line organization loss
12. Logistic loss
13. Measurement and adjustment loss

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KK PILLAR

16 Major Losses--Category wise

D) 3 Major losses preventing efficiency of material and

energy (14 to 16)

14. Yield loss

15. Energy loss
16. Die and tool loss

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 TPM
KK PILLAR Examples Of losses

Match the pairs

Column A Column B
1. Conveyer not working A. Line Organization Loss
2. Changing Top FIN Die B. Minor Stoppages (Other)
3. Die grinding C. Shutdown Loss
4. No Power D. Logistic Loss
5. Press Jam (Operator Mistake) E. Equipment failure loss
6. P/S Under/Run F. Die/Jig/Tool Loss
7. JH Activity G. Defect Loss
8. Die Spray not available F. Tool change Loss
9. Billet Feeding Problem H. Start up Loss
10. Die Heating Shift Change I. Management Loss
11. Die Heating Break Down J. Measure & Adjustment Loss

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 TPM
KK PILLAR Losses Segregation

 All the thirteen losses have been categorized in to three different loss categories, they
are as follows
Loss Category Relation with OEE Loss
Equipment failure loss
Tool Change Loss
Down Time Losses Availability Startup Loss
Setup Adjustment Loss
Minor Stoppages
Management Loss
Die/Jig/Tool Loss
Speed Loss
Motion Loss
Speed Losses Performance Logistic Loss
Line Organization Loss
Quality Losses Quality Measure & Adjustment Loss
Defect Loss

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 TPM
KK PILLAR OEE Calculation

Calculate OEE and Shutdown loss?

MACHINE DATA VALUES

Shift Length 480 Minutes
Downtime 120 Minutes
Net Available Time 420 Minutes
Standard Cycle Time 1 Part per 14.5 Secs
Total Count 1150
OK Count 1140
Target Counter 1300

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 TPM
KK PILLAR OEE Calculation

–
• Availability = ( )x100

–
Availability = ( )x100

Availability = 71.42%

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 TPM
KK PILLAR OEE Calculation

• Performance =

Actual Cycle Time =

Uptime = Net Available Time – Down Time

= 420-120
=300 Minutes

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 TPM
KK PILLAR OEE Calculation

Actual Cycle Time =

Actual Cycle Time = 15.7 Sec

• Performance =

.
=
.

Performance = 92.3 %

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 TPM
KK PILLAR OEE Calculation

Ok Production
• Quality = Total day production
100

= 100

Quality = 99.13%

OEE = Availability x Performance x Quality

OEE = 71.42% x 92.3% x 99.13%
OEE = 65.3%

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Journey Continues......

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