TOTAL PRODUCTIVE MAINTENANCE AND TOTAL PROCESS CONTROL IN HEAT TREATMENT INDUSTRIES M.Vijayananthan (M.E Engineering design) RVS Educational Trust s Group of Institution, Dindigul, Tamil nadu. (vijayananthan50@gamil.com) ABSTRACT This paper will review the goals and benefits of implementing Total Productive Maintenance, and it will also focusing on calculating the overall equipment effectiveness in heat treatment Company in Coimbatore, and it also discuss what called the big six losses are involved in industries (the quality, availability and speed). A case study taken from a heat treatment companies in Coimbatore, the data taken along all the working days and teams formed in period of two months to find out the benefit of formation a multidiscipline team from different department to eliminate any boundaries between the departments and make the maintenance process more effectively, labors on the production line also included in way to adopt the autonomous maintenance operations (yearly maintenance). As a result the company achieved 99% in quality factor of overall equipment effectiveness equation and 76% in availability where in performance it got 72%. Set of techniques like Single minute exchange die, computer maintenance management system, and production planning were suggested to the industry after calculating the OEE to improve their maintenance procedures and improve the productivity. Total process control has four important parameters such as man, money, machine, material. TPC is generally focusing some goals such as reduce waste through increased accuracy of machine control. I. INTRODUCTION In the last years the maintenance was traditional activities where all companies applying it without knowing its importance, but after the improving in production strategies and improve the flexibility of production line to produce a wide range of different products, the need for good maintenance strategy becomes bigger, and in the present times especially, because of automation and large-scale mechanization, higher plant availability, better product quality and long equipment life had assumed considerable significance. Now many companies have shifted their focus to optimize their assets, and use equipment s more effectively, and one of the main parts of the company which has a strong influence on the assets is the maintenance department or the employees responsible for maintenance. Total productive maintenance (TPM) is new maintenance strategy developed to meet the new maintenance needs, TPM is an American style of productive maintenance which has been modified and improved to fit in the Japanese industrial environment. Now it is popular in Japanese industry and in other western countries. It is closely tied to JIT (Just in ) and TQM (Total Quality Management) and it is extension of PM (preventive maintenance), where the machines work at high productivity and efficiency, and where the maintenance is all employee responsibility, and focus to prevent the problem before it may occurs. TPC is known as total control process. It has four parameters such as man, money, machine, materials. These parameters are known as 4m. In every parameter are has to own duties. The TPC method play vital role in controls the total processes as done by the heat treatment companies II. LITERATUREREVIEW TOTAL PRODUCTIVE MAINTENANCE REVIEW AND OVERALL EQUIPMENT EFFECTIVENESS MEASUREMENT Osama TaisirR.Almeanazel Department Of Industrial Engineering, Hashemite University, Zarqa, 13115 Jordan Abstract This paper will review the goals and benefits of implementing Total Productive Maintenance, and it will also focusing on calculating the overall equipment effectiveness in one of Steel Company in Jordan, and it also discuss what called the big six losses in any industry (the quality, availability and speed). A case study taken from Steel Company in Jordan, the data taken along fifteen working days and teams formed in period of two months to find out the benefit of formation a multidiscipline team from different department to eliminate any boundaries between the departments and make the maintenance ISSN: 2393-9184 12
process more effectively, labors on the production line also included in way to adopt the autonomous maintenance operations (daily maintenance). As a result the company achieved 99% in quality factor of overall equipment effectiveness equation and 76% in availability where in performance it got 72%. Set of techniques like Single minute exchange die, computer maintenance management system, and production Planning were suggested to the industry after calculating the OEE to improve their maintenance procedures and improve the productivity III. EXPERIMENTAL SETUP III.I. VISITING OF HEAT TREATMENT INDUSTRIES BEST HEAT TREATMENT SERVICES ` 53, Sidco industries estate, Coimbatore 641 021 Ph. 0422-2672126 No of furnace Maximum temperature Cooling medium Material Testing method Production Delivery time Cooling rate Types of furnace Electrical & Electronics maintenance Heating time Shift Startup loss Design cycle time Shift length Short breaks and Meal break Down time Ideal run rate Total pieces and Reject pieces METALLURGICAL ENGINEERING INDUSTRIES C-8, Pvt Industry s estate, Coimbatore 641 021. Ph. 0422-2672225 COVAI METAL TREATERS A-11, Private industries estate, Sidco, kurichi, Coimbatore 641 021 Ph.2676051 THE METAL INDUSTRIES LIMITTED Metined Nagar, Shoranur- 679 122. Palakkad (DT), Kerala. TECHNOTHERM INDUSTRIES 645/1, ThillaiNagar, Eachanari (po), Coimbatore- 641 021 Ph. 0422-2672898 INDOTHERM TECHNOLOGIES No.160-A, Saradha mill road, Sundarapurampost, Coimbatore 641 024 III.II. HEAT TREATMENT INDUSTRIES - IMPORTANT PARAMETERS Area (or) Plant Investment Mechanical Maintenance Tonnage capacity Rejection III.III. COMPANY DETAILS INDUSTRY-I (EXAMPLE I) Area (or) Plant 3000 sqft Investment 60 Lakhs Mechanical Weekly once Maintenance Tonnage capacity 1 tone/day Rejection Nil No of furnace 3(GCF,VACF) Maximum C 700-1000 temperature Cooling medium Water, Air quenching Material Except from HSS Testing method Impact, Brinell,Rockwell hardness Production Service only Delivery time 2 days Cooling rate 1:10 Types of furnace 1Liquid nitrating, oxidation Electrical & 1 Weakly once Electronics maintenance Heating time Depends upon materials Shift 3 Startup loss 5 hrs. Design cycle time Nil Shift length 24 hours = 1440 min. Short breaks 6 @ 15 min = 90 min. Meal break 3 @ 30 min = 90 min. Down time 90 minutes Ideal run rate 4 pieces per minute Total pieces 4500 pieces Reject pieces 170 pieces ISSN: 2393-9184 13
IV. THE FORMULAS OF OEE As described in World Class OEE, the OEE calculation is based on the three OEE Factors: Availability, Performance, and Quality. Here s how each of these factors is calculated. Availability Availability takes into account Down Loss, and is calculated as: Availability = Operating / Planned Production Performance Performance takes into account Speed Loss, and is calculated as: Performance = Ideal Cycle / (Operating / Total Pieces) Ideal Cycle is the minimum cycle time that your process can be expected to achieve in optimal circumstances. It is sometimes called Design Cycle, Theoretical Cycle or Nameplate Capacity. Since Run Rate is the reciprocal of Cycle, Performance can also be calculated as: Performance = (Total Pieces / Operating ) / Ideal Run Rate Performance is capped at 100%, to ensure that if an error is made in specifying the Ideal Cycle or Ideal Run Rate the effect on OEE will be limited. Quality Quality takes into account Quality Loss, and is calculated as: Quality = Good Pieces / Total Pieces OEE OEE takes into account all three OEE Factors, and is calculated as: OEE = Availability x Performance x Quality IV.I. FORMULAS TO CALCULATING OEE (ANOTHER METHOD) OEE is equal to the multiplication the three main bases for the six big losses: OEE = Availability * Performance rate * Quality rate (a) Mechanical breakdown (b) Electrical breakdown (c) Electronics breakdown (d) Total breakdown = (a) + (b) + (c) (e) Setup and other condition (f) Total loss = (d) + (e) (g) Total good hours (h) Net loss = (g) (f) Availability indicates the problem which caused by down time losses. Availability = Required availability Down time / = Required availability * 100 (i) Availability rate = (h) / (g) *100 Performance indicates the losses caused by speed losses. Performance rate = Design cycle time * output/ Operating *100 (j) Management loss (k) Startup loss (l) Performance rate = (h) ((j) + (k)) Quality indicates the scrap and rework losses. Quality rate = production input Quality defects / production input * 100 (m) Total breakdown (n) Production or quantity of heat treated parts per shift (o) Defected heat treated parts =(m) * (n) (p) Total production or Total quantity of heat treat treated parts in three shifts (q) Defected heat treated parts (r) Percentage of quality = (p) (o) (s) (OEE) Overall Equipment Effectiveness = (i) * (l) * (r) * 100 IV.III. OEE CALCULATION OF HEAT TREATMENT INDUSTRIES 7.2.1 INDUSTRY-I (EXAMPLE I) The below contains hypothetical shift data, to be used for a complete OEE calculation, starting with the calculation of the OEE Factors of Availability, Performance, and Quality. Note that the same units of measurement (in this case hours and pieces) are consistently used throughout the calculations. Item Shift Length Short Breaks Meal Break Down Ideal Run Rate Total Pieces Reject Pieces Planned Data 24 *365=8760 hours/year 6 @ 15 min/day=1.5*365=547.5 hours/year. 3 @ 30 min/day=1.5*365=547.5 hours/year. 1.5 hours/day=1.5*365=547.5 hours/year 300 pieces per hours. 16,42,500 pieces 62,050 pieces Production = Shift Length -Total Breaks = 8760 1095 ISSN: 2393-9184 14
Operating = 7665 hours. = Planned Production - Down = 7665 547.5 = 7117.5 hours. Good Pieces = Total Pieces - Reject Pieces Availability Performance = 16,42,500 62,050 = 15,80,450 pieces = Operating / Planned Production = 7117.5 hours / 7665 hours. = 0.9285 or 92.85% = (Total Pieces / Operating ) / Ideal Run Rate = (16,42,500 pieces / 7117.5 hours) / 300 pieces per hours = 0.7692 or 76.92% Quality = Good Pieces / Total Pieces = 15,80,450 / 16,42,500 pieces = 0.9622 or 96.22% OEE = Availability x Performance x Quality = 0.9285 x 0.7692 x 0.9622 OEE = 0.6872 or 68.72% V. OEE GRAPH Heat treatment industries vs.percentage of OEE HEAT TREATMENT INDUSTRIES % OF OEE BEST HEAT TREATMENT SERVICES 68.72% METALLURGICAL ENGINEERING 74.13% INDUSTRIES COVAI METAL TREATERS 74.40% THE METAL INDUSTRIES LIMITTED 76.97% TECHNOTHERM INDUSTRIES 77.31% INDOTHERM TECHNOLOGIES 79.34% Table 8.1. percentage of OEE VI. TOTAL CONTROL PROCESS Total Control Process is known as total control process. It has four parameters such as man, money, machine, materials. These parameters are known as 4m. In every parameter are has to own duties. The TPC method play vital role in controls the total processes as done by the heat treatment companies. MAN Human resource is a foundation of heat treatment companies. Man can control the every process in the heat treatment companies. The man power can decide to increase the production, quality etc. The total human resources in a heat treatment company only can make impact on the customer. Only man can satisfy customer s need. The man can make good result in servicing. MACHINE In every machine are having three each duties In heat treatment companies the machines are reducing the man hours. The machines are increasing the production. So that heat treatment companies are earning money. The machines are making the impact on the customer by delivery the product at right time. MATERIAL Materials are important for making a product Materials has two classification such as ferrous and non-ferrous ISSN: 2393-9184 15
In heat treatment process some companies are using HSS material with vacuum tube setup. For aluminum heat treatment BDF furnaces are using 9.4 MONEY Money is important factor for making an establishment Money playing very important factor in a heat treatment company and it can decide the future also Money can express in more ways such as prime cost, production cost, selling cost etc. In a heat treatment company money has two resources such as direct investment and indirect investment VII. FINDINGS IN TOTAL PRODUCTIVE MAINTENANCE We are all visited some heat treatment companies for to get guidelines. According to our view we can saw the companies should followed TPM procedures. We list the findings and details regarding TPM process. The machines are worked continuously for finish the jobs in companies. So they have to meet some major issues. More companies tried to maintain the perfection and discipline. So they have to follow the TPM process. The furnaces are meets some mechanical breakdown. During that time rope may be break and bearing may be wear so the works get delay one day. Sometimes electrical breakdown also appear. Because the variations and fluctuations of voltages may be cause of electrical breakdown. According to our view only 2% chance to get electric breakdown VIII. FINDINGS IN TOTAL PROCESS CONTROL Total control process also play vital role in heat treatment companies. The companies are following TPC. They should maintain the company by several methods such as, Some companies are appointed more workers to finish a small job so they had lost their money. Some companies are not interest to appoint more workers so job may be delaying. Some workers not have proper training and experiences. Some companies have special type machines and furnaces. So the machines are handled very carefully so machines are may be easily corroded and wear. In every company they should keep UTM, Brinell hardness testing machines. Sometimes workers cannot use the machines properly. So companies are suffered the rejection of materials due to lack of training and experiencing. Almost every company wants to heat treatments on cast iron. They won t use the HSS materials for heat treatment. An additional vacuum tube is need for the heat treatment of HSS materials. Money is another important part of a TPC. So companies are investing more money to buy the machineries. Some of the companies are follows the economy strategy to target the profit. They should perfectly use their working space. They are invests or involves more useful activities. A few companies are not interested to make more profit. The heat treatment companies are tries to satisfy the costumer need. IX. DISCUSSION In Heat treatment companies they never thought to have system which calculates their performance while they have a standard OEE since the installation of the line. But without calculated it we cannot improve it, we saw the performance of the companies as overall equipment effectiveness is 75.15%, where the availability of the line was 93.05% of the production time and the performance was 85.94 % while the quality factor is 97.13%. Table 5 shows the comparison between world class measurement and the companies measurement. Table 4. The comparison between WCM and company OEE OEE World class Companies Availability 93.05% 90% Performance 85.94% 95% Quality 97.13% 99% ISSN: 2393-9184 16
As we see from the table 4 the companies achieved the world class quality factor, and as presented above the company had ISO 9001:2000 certificate in 2005, and they are applied a strong quality measurement and inspection system start from the raw materials inventory to the work in process finished with finish goods inventory. But the company needs to work hard to improve their system machines and reduce the waste time. employing more technologies. The workers are not involving for increase the production. The heat treatment companies are having any alternative tools for maintenance. investing money to maintain the TPM procedure. Heat treatment companies are not following right way of OEE calculation. interesting to promote modern techniques of electronic maintenance. promoting vacuum controllers. So that the heat treatment companies can t make use of HSS material for heat treatment process. X.SUGGESTIONS The first activity in any assessment of performance is to determine the current operating parameters. Where are we today? What system do we have in place, and how do they work? What current condition of the plant and equipment? Are we starting from scratch, or do we have workable systems that only need to be improved? Total productive maintenance is an extension of the quality management philosophy to the maintenance function. Seven basic steps get an organization started toward TPM: Management learns the new philosophy. Management promotes the new philosophy. Training is funded and developed for everyone in the organization. Areas of needed improvement are identified. Performance goals for formulated. An implementation plan is developed. Autonomous work groups are established. There is no single correct method for implementation: however, these steps will provide a good framework. XI.CONCLUSION By implementing the TPM strategy they can eliminate most of the waste happened like the time waste while changeover or the downtime losses, with this maintenance strategy the responsibility of maintain the equipment is all operator and engineering responsibility, there will be no more "his or my" fault the break down will be solved as fast as possible. The operator in the shop floor should involve in each maintenance operation because he is the one close to the machine and he know what are the abnormality of the machine. There are three main techniques will have a very good impact to improve the production line and make the maintenance process more effectively, CMMS, production planned, and SMED, those techniques will help the company to operate at high rate of performance without losses. The project gives new huge step to the company in calculation the performance and how they can focus on the problems, when we formed a group from each department the company got a chance to see how the team work is important in solving the problem. Another benefit of the project is to give them the chance to know what the best techniques that they can apply which will improve their performance. Calculating the OEE also give the company where they are and where is the weakness point and how to improve REFERENCES Rajiv Kumar Sharma, Dinesh Kumar and Pradeep Kumar, "Manufacturing excellence through TPM implementation: a practical analysis", Industrial Management & Data System, Vol. 106 No. 2, 2006, 256-280. Terry Wireman, Total Productive Maintenance, 2nd edition, 2004. Muhammad ShahidTufail, Investigation of the ways to improve the performance of a plant, Växjö University School of Technology and Design, 2007, http://www.vxu.se/td. Heinz P. Loch, "Improving machinery reliability", 1998. C.J. Bamber, P. Castka, J.M. Sharp, Y. Motara, "Cross-functional team working for overall equipment effectiveness (OEE)" Journal of Quality in Maintenance Engineering, Volume 9 Number 3, 2003, 223-238. Nich, Rich total productive maintenance: lean approach, 1999, Tudor Business limited. ISSN: 2393-9184 17
E. Nadarajah, M. Sambasivan, S. Yahya, "Autonomous Maintenance An Effective Shop-Floor Tool to Improve Productivity, Institute of Technology Management and Entrepreneurship KolejUniversitiTeknikalKebangsaan Malaysia, 2006. Nakajima S., Introduction to TPM, productivity press, Portland, 1988. Mobley R. K, An introduction to maintenance, 2nd ed,usa, 2002. Bamber, "Factors affecting successful implementation of total productive maintenance'', MSc Research Dissertation, University of Salford, 1998. C.J. Bamber, J.M. Sharp and M.T. Hides, "Factors affecting successful implementation of total productive maintenance A UK manufacturing case study perspective", Journal of Quality in Maintenance engineering, Vol. 5 No. 3, 1999, 162-181. Wireman T, computerized maintenance management systems, 1994, 2nd ed, New York,USA. Willmott, P, TPM: Total Productive Maintenance: The Western Way, Butterworth-Heinemann, 1997, Oxford. ISSN: 2393-9184 18