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Breakdown time Reduction of Case Differential Machining Line
By practicing
Total Productive Maintenance (TPM)

A Dissertation Proposal for

Management Programme

By
Manoj Kumar Rana

Enrolment Number: 17070745420
Under the guidance of

Sudhir Sharma

Gurgaon-122001

SYNOPSIS

1. Introduction—
1.1 Self-- I am Manoj Kumar Rana is presently working with Corwn Berger ,Kenya. I was working in Sona Koyo Steering Systems Ltd, Gurgaon as a Assistant General Manager – Quality System. My role was to implement Continuous improvement tools is the organization
1.2 Organization: Sona Koyo Steering Systems Ltd. Gurgaon is India’s largest steering systems manufacturing concern. Company has been awarded “Deming Prize” in December 2003. It is the first company in North India, which is awarded by Deming Prize.

Sona Koyo is an ISO/TS16949:2002, ISO 14001 certified company and is in technical collaboration with JTEKT corporation Japan, which is world’s largest steering systems manufacturer.

Sona Koyo has been awarded the TPM Excellence Award in the year 2008 by Japan Institute of Plant Maintenance (JIPM) for recognition of excellence in operation by following TPM practice in the organization

Major Customers-- Maruti Udyog Ltd., Hyundai Motors India Ltd., Toyota Kirloskar Motors Ltd., Tata Motors Ltd., JTEKT Japan, General Motors (U.S & India), Fuji Autotec (France), Mahindra & Mahindra Ltd., Lotus Club car UK.

1.3 Mission of the company is “Create a Company That India is Proud of”

1.4 Sales turnover and employee strength: Sona achieved turnover of 750 crores in F-08. Total 950 people work including workmen, Engineers and Managers
1.5 Products of the company:

2. Project Undertaken:

Breakdown time reduction in case differential machining line
As we know that there is a great competition in the Indian market and Customer has become more knowledgeable about the product and services. Most of the European and Asian countries are directly coming to India for making their cars like Toyota, Hyundai, Nisan, Honda, GM, Ford, Fiat etc.
Cost reduction is a must requirement to survive in the era of Global competition because customer is asking cost reduction every year.So we can reduce the cost of product through the down time reduction. That is why I have taken this project for productivity improvement.

Picture of Rear Axle Assy.

3. Objectives of this project

• Reduce down time of Case Differential-II Machining Line.
4. Reason for selecting of topic of breakdown time reduction
Case Differential-II Machining line, we are operating in all three shifts (A, B and C shift). Total time available for operation is 21 Hrs. for all three shifts excluding breaks time (Lunch, Tea etc.). Monthly production from this line is 22500 with current cycle time 72 seconds at 80% Overall line efficiency. A and B shifts are 7.5 Hrs. each, C shift time is 6 hrs.
So we want to make same quantity of the month in two shifts (A and B) in 15 hours through Breakdown Time Reduction.
5. Research Methodology
5.1 Breakdown time reduction:
This is defined as reduction in non-productive hour by eliminating down time of the line. Our measure of reduction in down time will be increasing the line availability for production.

5.2 Methodology for reduction in Breakdown time:
TPM practice is the best way to prevent machine breakdown & other losses. So in this project I have also adopted the TPM methodology. There are 8 pillars of TPM to control the different losses:

|S.N. |TPM Pillars |Department responsible |Losses to be taken care |
|1 |Jishu Hozen (Autonomous Maintenance) |Production |Breakdown |
|2 |Planned Maintenance |Maintenance |Breakdown |
|3 |Quality Maintenance |Quality Assurance |Defects/Rejections |
|4 |Kobetsu Kaizen (Individual Improvements) |Engineering |Motion Losses |
|5 |Development Management |R&D |Development Losses |
|6 |Office TPM |Purchasing |Inventory Losses |
|7 |Education & Training |HR |Losses due to poor skill/Knowledge |
|8 |Safety health & Environment |Personnel & Administration |Accidents related losses & Environmental |
| | | |Losses |

Being a production manager I have selected the Jishu Hozen (Autonomous Maintenance) pillar to prevent the machine breakdown on Case Differential line-II

5.3 TPM Jishu Hozen (Autonomous maintenance) seven steps technique:

Step-1: Cleaning and inspection.
Step-2: Countermeasure for the cause of force deterioration and improving hard to access area.
Step-3: Preparation of tentative autonomous (jishu hozen) standards.
Step-4: General inspection.
Step-5: Autonomous inspection.
Step-6: Standardization.
Step-7: All-out autonomous management

5.4: Description of the problem:

Average monthly down time of the Case Diff. Line is 17.5 % as shown in below graph. So line availability is very low. Due to low availability of the line, we are unable to meet the daily customer requirement. Case differential –II line is also a multi model line and meet the multi customer requirement.

5.5: Data Collection: (Apr-09 to Jul-09)

Line Layout

[pic]

Above two graphs shows that line down time due to machines breakdown is highest i.e. 9.3% as compare to other down time categories and breakdown frequency is also high. So high machine breakdown time as well as high breakdown frequency is a critical problems in meeting the customer supplies. Plant efficiency is also low i.e. 82.5% due this down time.

[pic]

5.6: Inference from above data:
It is found that the Case Differential-SPM-II line has high machine breakdown time (9.3%). There are two machines which are contributing 80 % of total machine breakdown time of the line. This down time has been affecting in frequent delivery delays to customers. Therefore, this line is chosen for conducting autonomous maintenance for preventing machine breakdowns.

6. Team Formation

|S.No. |Name |Department |Responsibility |
|1 |Manoj Rana |Production |Coordinator |
|2 |Vipender Singh |Production |Leader |
|3 |Balwan Singh |Production |Member |
|4 |Shmasher Singh |Production |Member |
|5 |Rakesh Sheoran |Production |Member |
|6 |Chandiram |Production |Member |

7. Target setting

|Parameter |Existing |Target |Effectiveness |
|Line breakdown time |9.3 % |1.9% |80% reduction |
|Line breakdown Frequency |33 nos. |7 nos. |80% reduction |
|Life efficiency |82.5% |89.5% |8.5% increase |

8. Activity plan • Defined time wise activity plan from Sep-09 to nov.-09

[pic]

9. Limitations • One week training on Autonomous Maintenance to be provided to team members. • For active involvement of people, Sr. management focus is essential. • After completion of project, team members must be rewarded for motivation of others.
10. Future directions for further Improvements • Follow PDCA approach- Plan, Do, Check, Act (Deming Cycle) in Jishu-Hozen. • Horizontal deployment of Jishu-Hozen practice in other lines also • If target not achieved, again redo the whole process and repeat it till the target is achieved.

11. Expected contribution from the study:

11.1 Tangible benefits: • Reduction in machine breakdown time. • On time delivery to the customer • Increase in line efficiency

11.2 Intangible benefits: • Improved moral • Customer satisfaction • Improvement in operator’s skill

12. Description of various literatures to be studied:

1. Maintenance management by P.Gopalkrishanan and Banerjee.
2. Books of Japan institute of plant maintenance.
3. TPM for operators by Kunio shirose
4. Introduction to TPM by Nakajima seichi.
5. TPM team guide by Shirose Kunio.
6. Equipment management by Gotoh Fumio
7. TPM case studies by Nikkan Kogyo Shimbun.

--- End of Synopsis ---

Name: Manoj Rana

-----------------------
Case Diff. Product of the Project subject

Rear Axle Assembly

Diff. Assy.

[pic]

Gun Drill

Cross Hole Drill

Cross Hole Boring

Cross Hole Chamfering

Multi Hole Drill

Multi Hole Tapping

Spherical Milling

Washing

R/M

F /M

Washing

[pic]

[pic]

Two Machines contributing 80 %

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