SFL - Krishnapuram

Kobetsu Kaizen

W elcome

Sundram

Fasteners
Madurai

Lim ited

(SFL)

Krishnapuram,

SUNFAST TPM

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SFL - Krishnapuram

Kobetsu Kaizen

Success through loss elimination approach of Kobetsu Kaizen

Presented by: S.M.Rajavikkiraman Sundram Fasteners Ltd Krishnapuram

SUNFAST TPM
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SFL - Krishnapuram

Kobetsu Kaizen

TPM implementation in SFL - Krishnapuram

Special Award 2008 Consistency Award
200 4

Excellence Award
199 8

Part 2

TPM kickoff
1995 SUNFAST TPM

Part 1
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SFL - Krishnapuram

Kobetsu Kaizen

TPM Part 1 and Part 2

Top Management

Planning

Finance

Personnel

General Admin

Production

Design & Development

Materials

Marketing

Plant 1

Plant 2

Plant 3

TPM Part 1: Main focus on factory TPM Part 2: Company wide TPM including all functions SUNFAST TPM
t

Courtesy:JIPM

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OTPM - Factor

Education & Traini

Planned Maintenance

Zero Accidents - Zero Defects - Zero Breakdowns Zero Losses

Kobetsu Kaizen

8-pillar approach to TPM implementation in Part 1

Jishu Hozen

5S (Seiri Seiton Seiso Seiketsu Shitsuke)

SUNFAST TPM

Quality Maintenance

SFL - Krishnapuram

Safety, Health & Environ

Kobetsu Kaizen

Initial Control - P

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Kobetsu Kaizen

Transition 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 pillars
SUNFAST TPM
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Education & Traini

OTPM - Factor

Planned Maintenance

11-pillar 2-tier approach to TPM implementation in Part 2

Hi Q Lo C Speed Customer Delight

Kobetsu Kaizen

SFL - Krishnapuram
Jishu Hozen

Safety, Health & Environ

Quality Maintenance

Kobetsu Kaizen

CCuusstotommee rr FFooccuus edd

IInnteterrnnaal l FFooccuus edd

Zero Accidents - Zero Defects - Zero Breakdowns Zero Losses

SUNFAST TPM

5S (Seiri Seiton Seiso Seiketsu Shitsuke)

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Initial Control-Equipme

Initial Control-Products

OTPM - Marketing

OTPM - Purcha

SFL - Krishnapuram

Kobetsu Kaizen

Step Change in Part 2

Level of Performance

Gradual improvement (Kaizen activities)

Step change (Innovative/breakthrough activities)

Gradual improvement (Kaizen activities)

Period of time
Part 1 Part 2
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SUNFAST TPM

SFL - Krishnapuram

Kobetsu Kaizen

Focus areas for Step Change in Part 2

Top 4 Pillars

Focus area

OTPM-Marketing IC-Products OTPM-Factory Kobetsu Kaizen (KK)

Strategies Technology Systems Methodology

SUNFAST TPM

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SFL - Krishnapuram

Kobetsu Kaizen

Focus areas for Step Change

Top 4 Pillars

Focus area

OTPM-Marketing IC-Products OTPM-Factory Kobetsu Kaizen (KK)

Strategies Technology Systems Methodology

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Kobetsu Kaizen

Success through loss elimination approach of Kobetsu Kaizen

SUNFAST TPM

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SFL - Krishnapuram

Kobetsu Kaizen

Success through Kobetsu Kaizen approach

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Kobetsu Kaizen

Objectives 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 improvements
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Kobetsu Kaizen

Objectives 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 improvements
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Kobetsu Kaizen

Methodology for total product cost reduction

Cost structure Loss structure Potential VA/VE

Establish relationship between 1. Costs and Losses 2. Costs and VA/VE

Loss-cost Relationship Matrix

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Kobetsu Kaizen

Cost structure
Total Product Cost

Raw material Cost

Conversion Cost
Tools Sub-contract Power Freight Outward Spares Chemicals Bought out service HSD Oils and lubricants Packing Materials Variable others

Employee Cost

Fixed Cost
Div.Heads Corp. over heads Special revenue Utilities & building Travel & conveyance Fixed others

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Kobetsu Kaizen

Loss structure
Losses 16 major losses Time losses
Losses affecting availability Job change time loss Breakdown loss Customer complaint loss Losses affecting performance rate Losses affecting quality rate Schedule downtime losses Management losses

New losses

Sub-contract loss

Resource losses
Inventory loss Energy losses Tool loss Yield loss Bought out service loss Premium freight loss

SUNFAST TPM
Eliminate

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SFL - Krishnapuram

Combine

Kobetsu Kaizen

Potential VA/VE improvements

Reduce

VA/VE Improvements

Simplify

Design VA/V E
Raw Material Tools

Process VA/V E

Machine Output VA/VE

Speed-up

Labour Productivity VA/VE

Lunch Time Style Running Automation Single Piece Flow Lines

Cycle Time Reduction Multi Cavity Enhance equipment capacity

Lunch Time Running

SUNFAST TPM

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Kobetsu Kaizen

Loss-cost relationship matrix

Relationship Rating Scale : 1 = Weak , 5 = Strong

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Kobetsu Kaizen

Methodology for cost reduction

Loss-cost Relationship Matrix

Evaluation of loss-cost values and fixing targets for Loss reductions and VA/VE improvements

Loss reductions and VA/VE improvements target

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Loss-cost evaluation and setting targets

Losses
Yield Loss
R s./M T BM T arget Sav ings BM T arget 18% 8%

VA/VE improvements
J/C Loss
275 mts. 75 mts.

Tool Loss
20% 5%

Energy Loss
250 KWh/M T 100 KWh/M T

Tool VA/VE
490 Rs/MT 1097 Rs/MT

Energy VA/VE
80 Rs/M T 250 Rs/MT

M/C Labour Output Productivity VA/VE VA/VE

412 Rs/M T 1238 Rs/M T 83 Rs/M T 304 Rs/MT

Major Cost

RM cost Tool cost Energy cost Fixed cost Employee cost

38,919 3,918 3,949 15,877 7,600

29,189 2,351 2,947 9,609 6,080

9,730 1,567 1,002 6,268 1,520

5 1 1 1 1

1 5 1 1 1

1 1 5 1 1

1 2 1 3 1

1 4 1 1 1

1 1 3 1 1

1 1 2 4 1

1 1 1 1 5

Relationship Rating Scale : 1 = Weak , 5 = Strong

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Kobetsu Kaizen

Yield loss (loss no. 16) reduction

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MT

Kobetsu Kaizen

Yield loss elements

250

200

Selected for further analysis

150

100

50

Process scrap 196

Defect Loss 38

Inventory Loss 21

Setting Scrap 17

Assorted PS 10

En bit los 10

Testing Scrap 8

MT

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MT

Kobetsu Kaizen

Yield loss elements

140

63%
120

100

37%
80

60

40

20

0 MT

Nut Process scrap 120

Bolt Proces scrap 76

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Kobetsu Kaizen

Methodology for process scrap reduction

Process scrap reduction

Nut

Bolt/Screws

Slug

Tapping swarf

Machining Burr

Trim Burr

Grinding swarf

Reduce slug thickness Piercing in forging

Burrless Tapping

Forge to final shape Reduce Machining stock

Burrless forging

Reduce Grinding stock

Reduce Face machining Reduce Bore machining

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Kobetsu Kaizen

Process scrap reduction in nuts

Kaizen implementation matrix
Elements 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 17

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SFL - Krishnapuram
Sample 25.0 Kaizen mm
AFTER
(Yield loss)

Kobetsu Kaizen

Process scrap reduction in nuts

25.0 mm EFOR B E

Yield = 79%

Yield = 89.2%

RM wt. 96.0 gms

RM wt.85.0 gms

New spring loaded die

26%

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SFL - 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 Kaizen

19%
Better

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Kobetsu Kaizen

Process scrap reduction in bolts

Kaizen implementation matrix
16

Elements I Eliminate Trim burr Reduce OD grinding Reduce collar machining Total I - Identified C - Completed

Formed version C 32 32

Make to net shape I 15 13 28 124 75 C 8 5 13

Make to near shape I 26 22 48 C 16 14 30

48 48

16.8% SUNFAST TPM

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SFL - Krishnapuram

55% Reduction Kobetsu Kaizen Process scrap reduction - Bolt

8%
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. 5

SUNFAST TPM 17.8%

16.8

45%
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Reduction

SFL - Krishnapuram Kobetsu Kaizen 1998-99 1999-00 Total yield loss reduction Krishnapuram plant 2000-01
2001-02 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 10
6

9.7%

Better

17

13 12

11.58 10.4 6 9.7 Tgt.

17.84 2

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SFL - Krishnapuram Kobetsu29189 Kaizen 38918 Resultant RM cost reduction Krishnapuram plant
Rs./MT

38918

38440

38012

37586

36980

35840

34980

34012

33856

32988

31586

39000

Better

37000

19% Reduction

35000

33000

31000

29000

27000

25000
Cost Tgt.

1998-99

1999-00

2000-01

2001-02

2002-03

2003-04

2004-05

2005-06

2006-07

2007-08

2008-09 - I 2008-09 - II

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Kobetsu Kaizen

Tool VA/VE improvements

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Kobetsu Kaizen

Methodology for Tool VA/VE improvements

Tool VA/VE improvements

Design improvement Identify high consumption / value tools

Tool life improvement Using higher grade material for tool Improved surface coating for tool

Re-cycling

Tool Manufacturing improvement Manufacturing cycle time reduction

Analysi s

Using low cost material

Identify design weakness

Substitute of low cost material in non working area

Optimize tool design

Improving the surface finish by changing process sequence

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SFL - Krishnapuram

COST Rs./M

Kobetsu Kaizen

Tool cost element-wise

1,400

1,200

Selected for further analysis

1,000

800

600

400

200

0 Rs./MT

ST EL TO LS E O 1,250

CA BI DES R 94 0

ROLLI NG DIES 78 6

TA PS 58 7

OTHER S 355

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COST Rs./M

Kobetsu Kaizen

Tool cost element-wise

350

300

250

200

150

100

50

0 Piercing Pin T rim dies Heading Insert Rs./MT 305 245 205

Nut forming insert 155

Punches

Dies

OT HERS

150

140

50

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Kobetsu Kaizen Kaizen implementation matrix

Tool 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 36

Tool VA/VE improvements Steel tools

Theme

Piercing Pin Trim Dies Heading Inserts Nut Forming Dies Bolt Forming Dies Punches Common tools Total I - Identified C - Completed

SUNFAST TPM

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Kobetsu Kaizen

Tool VA/VE improvements Piercing pin

Sample Kaizen Split design
Phase 1 - Improvement
Split design with common material (HSS)

Phase 2 - Improvement Split design with LoC material

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Length optimization
No s 2 50 00 2 00 00 150 00

Kobetsu Kaizen

Tool VA/VE improvements Piercing pin

Optimum length: 1.1D to 1.3D

D
Failure mode: Buckling Failure mode: Breakage

100 00 50 00 0 1.6D 1.5D 1.4D 1.3D 1.2D 1.1D 1D 0.9D 0 .8D 0.7D

Length
Result : Tool cost savings up to Rs 1.2 million / Year ( 3.5 million yen/ Year).

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Kobetsu Kaizen Kaizen implementation matrix

Theme 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 38 203

Tool VA/VE improvements All Tools

Steel tools Carbides Rolling Dies Taps Other tools Total I - Identified C - Completed

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SFL - Krishnapuram Kobetsu Kaizen Cost savings through Tool VA/VE improvements
Rs./MT

1200

1000

Better

928
800

600

89% Improvement 490

400 1998-99 1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 09Cost / MT Target 490 490 520 590 610 670 697 720 786 840 870

2008-09- 2008I 928 1097 II

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3918 3918

3840

3750

3610

3560

3420

3315

3150

3010

2850

2480 2351

SFL - Krishnapuram Kobetsu Kaizen Resultant tool cost reduction Krishnapuram plant
Rs./MT
4500 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 Better

34% Reduction

SUNFAST TPM

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Kobetsu Kaizen

Labour productivity VA/VE improvements

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Kobetsu Kaizen

Labour productivity VA/VE improvements methodology

Labour productivity VA/VE Improvement

Lunch time style running

Coupling of machines

Automation

Single piece flow lines

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Kobetsu Kaizen

Lunch 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 loss

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Kobetsu Kaizen

Methodology for Lunch Time STYLE Running

Lunch Time Style Running

TPM Part - 2
Perfect Cell

Multi Line Operation

Informatio n System

Support Team

Perfect Lines

TPM Part - 1
Perfect Machines Coupling of Machines

Zero 1A/1B

Zero Defects

Zero Minor Stops

SUNFAST TPM

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SFL - Krishnapuram Journey to Lunch Time Style Running PRE-TPM

LUNCH TIME STOPPING

Kobetsu Kaizen

TPM Part 1
LUNCH TIME RUNNING

TPM Part 2
LUNCH TIME STYLE RUNNING

6 Machines 6 Operators Lunch Time stop Machine concept

3 Lines 3 Operators Regular : 3 Op & Lunch Time :1 Op. Line concept

1 Cell 1 Operator Regular, Lunch Time : 1 Op. Cell concept

SUNFAST TPM

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SFL - Krishnapuram F FORGING MACHINE R

Kobetsu Kaizen
ROLLING MACHINE OPERATOR

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Kobetsu Kaizen

Problem / present status

We have 3 lines of forging and rolling which are coupled Each line has got a dedicated operator Labour productivity is low
Rolling machine

Operator 3

Operator 2

Operator 1

Forging machine

Line 3

Line 2

Line 1

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Kobetsu Kaizen

Countermeasures
Eliminate 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 team

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Kobetsu Kaizen

Lunch Time Style Running

Sample Kaizen 84S1, 84S2 and 84S 3
BEFORE LAYOUT MODIFIED LAYOUT

Operator 3

Operator 2

Operator 1

Operator 1

Line 3

Line 2

Line 1

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Kobetsu Kaizen

Lunch Time Style Running

Responsibilities for Operator and Support team
OPERATOR RESPONSIBLE FOR ALL ACTIVITIES DONE ON ROUTINE BASIS SUPPORT TEAM RESPONSIBLE FOR EXTERNAL AND SPECIAL ACTIVITIES

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Kobetsu Kaizen

Information system
LTSR - Information system
Support required from Supervisor/Manager Support required from Kaizen Team Machine is in Running

Audio

Light Signal with Alarm

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Kobetsu Kaizen

Result
Labour productivity index
800 639

600

400

213 200

100

0 Index

Pre-TPM 100

TPM Part 1 213

TPM Part 2 639

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Kobetsu Kaizen

Benefits

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SFL - Krishnapuram Cost savings through labour productivity VA/VE improvements

Rs./MT

Kobetsu Kaizen
Better

350 300 250 200 150 100 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 92 102 108 118 126 132 138 145 168

243

260% 83
2008-09- 200809- II I 243 304

SUNFAST TPM

17 % Reduction

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SFL - Krishnapuram Kobetsu Kaizen Resultant employee cost reduction Krishnapuram plant

1999-00 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 6000

Better

5500

6080 SUNFAST TPM

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SFL - Krishnapuram Kobetsu Kaizen Total product cost reduction Krishnapuram plant
100
18% 27% 30%

80 % 60
100

40

82 73 70

20

0
Product cos t %

BM (1998-99) 100

Cons is te ncy (2004-05) 82

Curre nt (2008-09) 73

Target 70

Against the target cost reduction of 30%, we achieved 27% so far.

SUNFAST TPM

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SFL - Krishnapuram

Kobetsu Kaizen

To Sum up

TPM
Part 2

It is wider!

TPM
Part 1
SUNFAST TPM

It is higher!! It is much bigger!!!

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SFL - Krishnapuram

Kobetsu Kaizen

Thank You
SUNFAST TPM
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