Company Profile Roots Industries Ltd (ril) Is A Leading Manufacturer

COMPANY PROFILE ROOTS INDUSTRIES LTD (RIL) is a leading manufacturer of horns in India and the 11th largest horn manufacturing company in the world, Head quartered in Coimbatore, India. ROOTS have been a dominant player in the manufacture of Horns, Casting products, Industrial cleaning machines, Precision products and other products like Electronic Horns, Brake Shoes, Brake Pads, Halogen Lamps, Relays, Melody Makers, Roots Parking Guide System, Piston & Rings, Flashes, etc., Since its establishment in 1970, ROOTS had a vision and commitment to produce and deliver quality products adhering to International standards. With a strong innovative base and commitment to quality ROOTS has occupied a key position in both International and domestic market as suppliers to leading OEMS and aftermarket. Now RIL is the first Indian and first manufacturing company in the world to get ISO / TS 16949 Certification based on effective implementation of QS 9000 Certification and VDA 6.1 Certification. Other certifications like E – Certification from Europe, ISO 14001 Certification, and Q1 Certification add crowns to it. Their competitors includes Bosch, Lucas-TVS,

Minda Industries, Harley & Co,

Vibrant Auto components, National Electric company, etc., Its customers include the massive automobile giants like Mercedes, Ford, Mitsubishi, Mahindra & Mahindra, Toyota, Fiat, Tata Motors, Bajaj Tempo Ltd, Kinetic Honda, TVS, Leyland, etc., TPM IN ROOTS: ROOTS have its strong desire in producing world quality products compete in the global market. It has assigned a lot of R&D activities to deliver high quality and innovative products satisfying the needs of its customers. To make it true, ROOTS has been involved in various activities like 5S, KAIZEN, ISO, etc. And to add a few to its milestone TPM activity has been started in ROOTS since 2005. The divisions of ROOTS experimenting TPM are RPCL, RMCL, ROOTS Component Division and ROOTS Horn Division. Now the ROOTS Industries are at KICK-OFF stage in implementing TPM. This project involves in the implementation of TPM in Model machine – PRESS MASTER PSPR20. Primarily 5s is the base and we found problems cannot be clearly seen when the work place is unorganized. Cleaning and organizing the workplace helps to uncover problems and making problems visible is the first step of improvement. Next we have to be involved in TPM in analyzing the machine, rectifying the sources of contamination, 1

abnormalities in equipments, their counter measures, fixing Tentative Standard. Our main goal is to increase the OEE which would increase productivity, Reduce maintenance cost, Improve reliability and maintainability, eliminating the defects at source through active employee participation.

PROCESS LAYOUT Testing Mechanical Electric Front Accessories Test Stamping Pressing Painting To Packing Coils Coil Fasteners, Scraps Electrical Quality Markets winding Testing cover horn components Checking plates, Assembly components Back ing Insulators, cover plates, Diaphragm plates Conductors

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TPM MODEL MACHINE The machine PSPR 20 is a pressing machine 30 ton capacity used upto 400 strokes per minute. This machine comprises of auxiliaries such as decoiler, straightner and scrap cutter. The machine is powered by an electric motor and operates with the assistance of pneumatic devices, centralized electrical control system. Machine is a self lubricating at an interval of one working hour. Decoiler decoils the sheet metal strip wounded as a coil and the straightner straightens the sheet metal strip by the use of consecutive rollers. The decoiler and straightner are controlled by using cam limit switches. The feeder unit feeds the sheet metal at every stroke and actuated by pneumatics. Scrap cutter cuts the out coming strip from the press for easy handling. The various process involved are piercing and blanking. The machine consists of gauges and meters for monitoring. This machine is used for making the Diaphragm plates, front cover plates and back cover plates by pressing. The sheet metal coil of required dimensions is fed through the 3

interchangeable dies of this machine. This machine produces from 1to 5 plates according to the thickness required per stroke.

TP M M O D E L M AC H IN E M AC H IN E N AM E : PR ES S M AST ER

M AC H IN E N O : PSP R 20

C AP AC IT Y AT 20 C R AN K AN G LE BEFO R E BD C . ST R O KE SH U T H E IG H T FR O M BO LST ER R AM A D JU ST M EN T TA BLE FA C E BO LST ER T H IC KN ES S H EIG H T O F TABLE SU R FAC E FR O M FLO O R ST R O KE PER M IN U T E FLYW H E EL EN ER G Y AT 100 S PM M O T O R ( V ariable spped drive ) ELEC T R IC A L S UPPY AIR PR ES SU R E AIR C O N S U M P TIO N AT N TP PER C LU TC H O PER AT IO N APPR O X IM A T E W E IG H T

: 30 T onnes : 25 m m : 250 m m : 40 m m : 560 m m X 300 m m : 90 m m : 800 m m : 100 - 400 : 200 m kg : 7.5 kw / 0- 1200 rpm : 415 v , 3 ph. , 50 H z : 5.5 BAR : 7.5 Lit. : 4000 kgs

FEAT U R E H IG H LIG H T S C R AN KSH AF T RU N S IN AN T I - FR IC T IO N B EAR IN G S C O N N E C TIN G RO D R U N S IN AN T I - FR IC T IO N B EAR IN G S R EC IR C U LAT IN G F LO O D LU BR IC AT IO N " T U R C IT E " LIN ED 8 P O IN T SLID E G U ID EW AYS M AIN M O TO R FW D -R EV . T H R O ' AN T I - PLU G G IN G SW IT C H

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M

R a m u n it

FRL TAG CLASSIFICATION

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OVERALL EQUIPMENT EFFECTIVENESS (OEE)

OEE = Availability x Performance Efficiency x Rate of Quality product

OEE is just a number for relative comparison of equipment performance. The real benefits come from using the factors of OEE, which lead to root cause analysis and eliminating the causes of poor performance. It’s all about collecting, trending,

Performance Efficiency is given by Performance efficiency =Rate efficiency x Speed efficiency. Rate efficiency (RE): Actual average cycle time is slower than design cycle time because of jams, minor recorded stoppages, small problems and adjustment losses etc. Hence output is reduced due to this.

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Speed (rate) efficiency (SE): Actual cycle time is slower than design cycle time because of high vibration etc. and hence output of the machine is reduced. Rate of quality products (yield): It is the percentage of good parts out of total produced. OVERALL EQUIPMENT EFFECTIVENESS (OEE) MODEL CACLULATION OEE = A x PE x Q PE=QUANTITY PRODUCED/ (SPM * PRODUCTION TIME) A= (TOTAL AVAILABLE TIME - NON VALID TIME)/ TOTAL AVAILABLE TIME Q=NO OF QUALITY PRODUCTS/QUANTITY PRODUCED

Day

Shift

C.NO

PE %

PE/Shift %

02/07

1

906025

76

76

For 2/7/09 OEE DATAS 1st shift • • • •

Availability %=455-155/455=73.95% Q=14000/14000=100% Performance Efficiency =14000/(80*230)=76% OEE =0.76*0.7395*1=50.41%

Day Shift Total time

PLANNED DOWN TIME

(min) Tea time Training (min)

Availabl Down Availability % Performance Quality OEE e Time Time (min)

(min)

455

155

efficiency % factor % %

time (min)

02/07

1

480

25

-

73.95

76

100

For 2/7/09 OEE DATAS 2nd shift • • • •

Availability %=460-95/460=79.35% Q=13680/13680=100% Performance Efficiency =13680/(60*300)=76% OEE =0.73*0.7935*1=62.68%

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50.1

Day Shift Total time

PLANNED DOWN TIME

(min) Tea time Training (min)

Availabl Down Availability % Performance Quality OEE e Time Time (min)

(min)

460

95

efficiency % factor % %

time (min)

02/07

2

480

20

-

79.35

73

100

62.68

For 2/9/09 OEE DATAS 1st shift • • • •

Availability %=455-80/455=82.41% Q=20100/20100=100% Performance Efficiency =20100/(65*375)=79% OEE =0.82*0.79*1=65.36%

Day Shift Total time

PLANNED DOWN TIME

(min) Tea time Training (min)

Availabl Down Availability % Performance Quality OEE e Time Time (min)

(min)

455

80

efficiency % factor % %

time (min)

02/09

1

480

25

-

82.41

79

100

TABLE – 8

CLRI IDENTIFICATION

8

65.36

CUMMULATIVE TAG MATRIX FLOW

CLRI TIME REDUCTION UNIT

Decoiler

Straightener

AREA

Bottom leg & coil holder Fan motor cover Motor Belt cover Total Removing cover 40 bolts

CLEANING TIME IN MINUTES BEFORE AFTER JH JH 3 3

TIME SAVED IN MINUTES

5 2 5 15

3 2 2 10

2

45

3

42

3 5

9

Press

Scrap cutter unit Total Time

Fan motor cover Motor Bottom cleaning Top side Total

5 2 2 5 59

0 0 2 5 10

FRL Oil filter Oil pump unit Feeder unit Left column Control panel Right column Air circuit Air reservoir Lubrication motor fan Machine frond end Ram side Bolster plate Fly wheel Fly wheel cleaning Total Time

2 1 2 4 7 1 2 2 25 6

2 1 2 1 7 1 2 2 1 3

2

2

5 3 240 6

5 1 2 6

2 238

308

38

270

5

2

3

387

60

327

Scrap cutter unit

5 2 49

3

24 3

CUMMULATIVE REDTAG MATRIX FLOW CLRI TIME REDUCTION CHART

CLEANING TIME FIG – 15

10

11

12

13

14

15

DATAS ACCIDENTS

BEFORE JH 0

STEP-0 0

STEP-1 0

STEP-2 0

STEP-0 10.8

STEP-1 13.1

STEP-2 7.66

ACCIDENT DATAS:

Break Down Hours

BEFORE JH 17.2

BREAK DOWN DATAS:

Break Down

Time in hours

20 15 10 5 0 BEFORE JH

STEP-0

STEP-1

STEP-2

QUALITY RATE CALCULATION: Before JH activity (Jan-09): •

Total number of components produced per month = 5,62,000

•

Total number of defective components in Dec month =230

•

QUALITY FACTOR = Q=NO OF QUALITY PRODUCTS/QUANTITY PRODUCED Q =(5,62,000-230)/ 5,62,000 = 99.959%

•

NUMBER OF DEFECTIVE PRODUCTS

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BEFORE Activities No of defective

JH 230

STEP-0 194

STEP-1 173

STEP-2 124

products

QUALITY QUALITY

BEFORE JH

STEP-0

STEP-1

STEP-2

RATE

99.959

99.965

99.969

99.978

QUALITY RATE:

99.98 99.975 99.97 99.965 QUALITY RATE

99.96 99.955 99.95 99.945 BEFORE JH

•

STEP-0

STEP-1

STEP-2

Quality rate is almost = 100%

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OEE ACHIVED BY IMPLEMENTATION OF TPM In the month of Before TPM OEE were found to be 50.85% During STEP – 0 ACTIVITY •

Time saved by carrying out of JH activity =1155 minutes

•

Valid time per month = 33410 minutes

•

Valid time during STEP – 0 =259050 minutes

•

Increase in valid time = 24905+1155 = 26060 minutes

•

Availability during STEP – 0 = 26060/33410 = 78%

•

Performance efficiency during STEP – 0 = 68%

•

OEE = 0.68*0.78*1.0 = 53.2%

•

Labour cost per hour= Rs 64

•

Cost saved = 1155*64/60 = Rs 1232

During STEP – 1 ACTIVITY •

Time saved by carrying out of JH activity =4218 minutes

•

Availability during STEP – 1 = 83.480%

•

Performance efficiency during STEP – 1 = 74%

•

OEE = 0.8348*0.74*1.0 = 61.78%

•

Cost saved =4218*64/60 = Rs 4500

During STEP – 2 ACTIVITY •

Time saved by carrying out of JH activity =1760 minutes

•

Availability during STEP – 2 = 86.7 %

•

Performance efficiency during STEP – 2 = 76%

•

OEE = 0.867*0.76*1.0 = 65.36%

•

Cost saved = 1760*64/60 = Rs 1880

OEE ACHIVED AND COST SAVED S.NO

Activity

Time saved

OEE achieved in %

Cost saved in Rs

1

Before TPM

in minutes -

50.85

-

2

STEP-0

1155

53.20

1232

18

3

STEP-1

4218

61.78

4500

4

STEP-2

1760

65.36

1880

TOTAL COST SAVED

OEE CHART:

BEFORE TPM

TPM

AFTER TPM

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ACTIVIT Y Before TPM STEP-0 STEP-1 STEP-2

ACCIDENT S

BREAK DOWNS

COST SAVED IN Rs/hr

0 0 0 0

17.2 10.8 13.1 7.66

1232 4218 1760

NO OF DEFECTIVE PRODUCTS

OEE IN %

230 194 173 124

50.85 53.2 61.78 65.36

TARGET ACHIEVED:

SUGGESTIONS: From the above charts and tables, it is clear that the implementation of TPM will be an effective process for the company. The implementation of TPM for the whole plant should be started now in parallel. So that the non-valid time will be reduced and the whole down time will tend to zero. Along with implementing TPM, SPC study should be done for all the bottle neck machines to find their statistical performance. The other manufacturing tools like Lean-six sigma, Value stream Mapping, Statistical Process Control had to be implemented in short to improve the plant performance. Due to globalization, the competition had been increased

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