Ravi Agarwal

8/4/2019 Ravi Agarwal

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A T O T A L P R O D U C T I V E M A I N T E N A N C E

A P P R O A C H

C E A T T Y R E S , M U M B A I

B H A N D U P P L A N T

R A V I A G A R W A L

I I T G A N D H I N A G A R

Banbury Mixer O.E.E. analysis


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Objective

Analysis of O.E.E. of Banbury mixer-2 using T.P.Mapproach.

OEE is a key metric in Total Productive Maintenance programsand gives us a consistent way to measure the effectiveness ofTPM and other initiatives by providing an overall framework formeasuring Production Efficiency.

O.E.E. lies between 40% to 85% World standard is 85% of Toyota.


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Banbury mixer3

Internal batch mixer

Raw material are mixed to form a basic semi-solidmaterial which is then extruded to form rubber

sheets.


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Total productive Maintenance4

A company-wide team-based effort to build quality intoequipment and to improve overall equipmenteffectiveness

Total

all employees are involved it aims to eliminate all accidents, defects and breakdowns

Productive actions are performed while production goes on

troubles for production are minimized

Maintenance keep in good condition

repair, clean, lubricate


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Overall Equipment Effectiveness5


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Planning V/s Reality8


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Abnormality analysis9


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Corrective measures11


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Kaizen12

kai means change, zen means good.

Small improvements on continual basis..

Major Kaizens at Ceat Plant-

Broken guards over machine parts to be replaced.

Unsafe work surroundings to be improved and properly

Re-designed. Improper design for cable routing to be properly designed.

Proper calibration of Pressure Gauges and other importantparts of Banbury mixer.


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One Point Lesson (OPL)14

Basic information sheet: essential basic information practical know-how and know-how of methods:

Maintenance activities as e.g. filter changing. Small repair works, cleaning, lubricating.

Major OPL to be implemented at Ceat Tyres, Bhandup plant are:-

Guarding the machine parts by aligning them properly. Damaged things to be immediately reported and replaced.

After finishing the job, tools and materials should be put back totheir original places. Proper arrangement of cable routing and avoiding cable slagging. Open cable should be immediately removed. Proper way of collecting oil and improve housekeeping.


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Make Standards16

Most important technique of implementing and sustainingTPM.

Done by making the important and basic neededimprovements as standards by documenting them.

Major Standards at Ceat Tyres:-

Standard for Proper Routing of cables. Standard for avoiding slagging of cables.

Standards stating removing of open cables. Standards for regular cleaning and improved housekeeping. Standards for identification of parts properly to avoid

hindrance in operation.


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For abnormalitiesdue to basicfaults

Typicalengineeringabnormalities


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Conclusion18

O.E.E. trends highlight the present state of manufacturingand resource utilization at CEAT tyres.

Average O.E.E. being 59% with world standard being 85%.

Abnormality analysis highlight the basic problems andpoint to the ultimate solution of an effective TPM approach.

Documents

Ravi Agarwal