TPM Manager
United Breweries Limited
Total years of experience :19 years, 7 Months
Responsible for the implementation, management, and successful operation of the Total Productive Management process in the plant.
Coordinates the development of the TPM preparation phase plan, tracks progress against the plan and leads issue resolution gap analysis and adjustments to plan
Implements appropriate reviews monthly, quarterly to evaluate all pillars and departments progress in their TPM plans
Oversees the individual pillars, sets benchmarks, and tracks completion of pillar goals, including participation in pillar meetings, team meetings and activities.
Will develop Pillar leaders and manage their development.
Coordinates activities with JIPM & CII consultants.
Serves as a TPM champion in the facility to promote TPM amongst management and employees “Culture Changes”.
Ensure that TPM work is impacting both results and the culture change towards the vision as determined by the plant zero loss journey, vision. including:
o Total employee involvement
o Leadership and coaching skills development
o Support of plant core values and norms
o Linkages of individual and team activities to losses and the business need
o TPM is the work TPM is the methodology for achieving manufacturing results
Key Deliverables:
Plant is progressing with TPM activities per the plant master plan. Plant is delivering the results improvements targeted by the plant master plan.
Education & Training on TPM and creating high awareness levels amongst Manager, Officers & workmen.
Driving TPM processes as a plant TPM Coordinator in divisions with the help of Managers / Executives.
Identifying Model Machine Line & motivating Managers / officers.
Driving and monitoring circle meetings / performance / participation / contribution.
Training to Managers and Officers on deployment of various TPM Edge.
Plan, develop, implement and carry out TPM process Audits internally.
Preparation for Monthly TPM DATA for Corporate Level and preparation of TPM Presentations.
Excellent Training Hands from Operator Level Local Language to Top Management regarding all TPM activities and Issues.
Implementation of TPM Pillar wise plan in JIPM way in the organization.
Responsible for Manager Model machine & Horizontal Deployment of TPM across the organization.
Responsible for Developing the TPM culture across the organization.
Formation of circles, creating awareness on TPM through regular trainings.
Ensure safe working environment.
Create an environment to implement continuous improvement.
Role as TPM Coordinator:
Responsible for the implementation, management, and successful operation of the Total Productive Management process in the plant.
Coordinates the development of the TPM preparation phase plan, tracks progress against the plan and leads issue resolution gap analysis and adjustments to plan
Implements appropriate reviews monthly, quarterly to evaluate all pillars and departments progress in their TPM plans
Oversees the individual pillars, sets benchmarks, and tracks completion of pillar goals, including participation in pillar meetings, team meetings and activities.
Will develop Pillar leaders and manage their development.
Coordinates activities with JIPM & CII consultants.
Serves as a TPM champion in the facility to promote TPM amongst management and employees “Culture Changes”.
Ensure that TPM work is impacting both results and the culture change towards the vision as determined by the plant zero loss journey, vision. including:
o Total employee involvement
o Leadership and coaching skills development
o Support of plant core values and norms
o Linkages of individual and team activities to losses and the business need
o TPM is the work TPM is the methodology for achieving manufacturing results
Key Deliverables:
Plant is progressing with TPM activities per the plant master plan. Plant is delivering the results improvements targeted by the plant master plan.
Education & Training on TPM and creating high awareness levels amongst Manager, Officers & workmen.
Driving TPM processes as a plant TPM Coordinator in divisions with the help of Managers / Executives.
Identifying Model Machine Line & motivating Managers / officers.
Driving and monitoring circle meetings / performance / participation / contribution.
Training to Managers and Officers on deployment of various TPM Edge.
Plan, develop, implement and carry out TPM process Audits internally.
Preparation for Monthly TPM DATA for Corporate Level and preparation of TPM Presentations.
Excellent Training Hands from Operator Level Local Language to Top Management regarding all TPM activities and Issues.
Implementation of TPM Pillar wise plan in JIPM way in the organization.
Responsible for Manager Model machine & Horizontal Deployment of TPM across the organization.
Responsible for Developing the TPM culture across the organization.
Formation of circles, creating awareness on TPM through regular trainings.
Ensure safe working environment.
Create an environment to implement continuous improvement.
Lead the Promotion Campaign for TPM:
Think of ways to keep the organization energized to move through the TPM journey
Set up mini celebrations of successes passing steps, success case studies, and competition: Best JH machine, Best KAIZEN, Best One Point Lesson, Best Improvement Each Month, Lines exceeding a true efficiency level.
Publish TPM Newsletter, OPL
Regularly Report plant progress to Top Management.
Integration of TPM pillar :
Develop an overall understanding of the different TPM pillars and how they integrate through the TPM master plan to deliver the improved results.
Train department and pillar leaders on this integration.
Develop a thorough understanding of the TPM efficiency basics and their integration to deliver increased efficiency.
Job Roles & Responsibilities : OTHERS
Vertical Startup Specialist by achieving Vertical startup of New equipment in less trial runs.
Plant machine maintenance (Mechanical, Electrical & civil) and utility services ( RO plant, ETP, STP, cooling towers, Fire equipments, pumps, water management, compressors, etc)
As a WCM Coordinator:
• Loss Identification of the plant & Process
• Conducting the Value Stream Mapping and Working for reducing Lead time on manufacturing.
• Driving the Cost Deployment, Risk Deployment and Cash deployment.
• Deriving the KPI’s and OPI’s for the pillars and functions.
• Champion of the Industrial Efficiency, Reliability, Innovation Development & Growth, Health and safety & Industrial Risk Prevention pillars.
• Guiding the Maintenance team to implement the WCM system approach.
• Guiding the Production team to maximize the productivity and eliminating non added value time via WCM approach.
• Guiding the Sales and Purchase team to implement the CASH deployment.
• Implementing and conducting the 5S across the plant.
• Conducting the Kaizen events as per schedule.
• Training SG Pillars concepts to all pillar champions and pillar members.
• Conducting the Audit for all pillars
• Coordinating and conducting Reward and recognition for employees.
• Implementing Kaizen & poke -yoke in order to improve productivity & cost saving
EH&S Coordinator:
• Coordinating EHS activity for the plant.
• Conduct plant wide Job Hazard analysis study for all machines & process.
• Conducting Energy Management Programs.
• .Implementing the Group EHS Standards in the plant
• Conducting the SMAT audit in the plant.
• Carrying out the Toxic Risk Management and updating in the portal.
• Implementing the CARE 4 EHS standard for the plant.
• Monitoring and Updating all Legal and other requirements.
• Conducting Mock drill, Firefighting training for all employees.
• Introduce the OCP and validating the same for Adequacy across the plant.
• Work Permit system management
• Member of the EHS 20 step internal auditor panel for Group level.
• Accident Investigation (6M) and updating in GAIA.
• Implementing the root causes for the anomalies and auditing for the effectiveness.
Achievements:
• WCM 2 Phases (Preparation and Pilot) has been successfully completed in the plant.
• Achieved Cost saving 3.1% in the Manufacturing cost.
• 15% increase in WCM score every year during the audit conducted.
• More than 330 Near misses are captured and converted as risk free Environment.
• .Obtained 58.03% in the EHS 20 step audit in 2010.
• 50% rise in the SMAT observations from 2010 to 2011.
•
Quality& TPM :
• Team Leader for Quality functions in Heat Treatment and Press Shop.
• Conduct plant wide Job Hazard analysis study for all machines & process.
• Conducting Energy Mangement Programs.
• Conducting SMED Programs across the plant.
• Implemented FFQ across the company
• Implmentation of Layered audit for all functions
• Implementation of SWOT for all functions and all work stations
•
EHS Coordinator:
• Conducting the Risk assessment along with zone champions
• Updating the Legal and other requirements and monitoring the same.
• Conduct plant wide Job Hazard analysis study for all machines & process.
• Conducting Energy Mangement Programs.
• Conducting internal audit for EHS management system.
• Conducting the Emergency Mock drill.
• Training the employees in the EHS requirements
• Accident Investigation and updation
• Chemical approval process as per Group Requirement.
• Creating SOP’s and Validating the same
Achievements:
• TPM has been successfully implemented in the Model machine.
• Lubrication oil cost 40K / month has been brought down in muller Press.
• Breakdown hours reduced from 40hrs/ Month to 08 Hrs/ month.
• Zero accident in the plant from July’08 to till date.
• More than 250 Near misses are captured and converted as risk free Envirnoment.
• Successfully Implemented Layered audit concept & SWOT function for all the process inside the plant
• Zero Deviation in EH&S System audit 2008 by INTECHENICA - Germany.
• Asia pacific First place in FFQ audit conducted by Schaeffler group in 2009.
• Brought down the Heat treatment shop internal PPM from 11000 PPM to 3727 PPM
As a Production Officer:
• Produciton Incharge for Assembly line.
• Operation and maintenance of Assembly machines - Stacker, Heat sealing and Group insertion etc
• Manpower allotment & Material Planning.
• Interaction with Vendors & Monitoring of Production at Vendor end.
• Production Planning & Control for over all plant.
• Over all Scrap Accounting & Control.
• Alloy Blending Production In charge
• Primary & Secondary metal Yield Calculation
• Inventory management and reduction
• Budgetting and manpower calculation
• Monitoring OEE for Equipments
• Analyzing breakdown of machine by applying analysis tool (PM analysis, FMEA, FTA, 4M- Analysis, Why Why Analysis, WWBLA, and SMED).
• MTBF & MTTR Monitoring
• Conducting JH activities in all area
• Implementing Kaizen & poka -yoke in order to improve productivity & cost saving
• Conducting Process FMEA,
• Conducting 5S Activities in Shop floor
• 5S Zonal Leader for Alloy blending.
• Coordinating the activities for Surveillance of TS16949:2002, ISO14001:2004,
OSHAS 18001:2007
Achievements:
• Increased the Produciton from 6MAH to 24MAH with existing facilities
• Implemented online Scrap handling system.
• Decreased SCRAP % from 4.06% to 2.3% over all plant.
• Increased the production of Alloy blending By 275MT
• Cost Saving to the company by 4Lacs/month
• Obtained Zero Accident in Alloy Blending & Scrap Handling
• Implemented Kaizen to improve the productivity.
• Acid filling ouput increased from 400 nos/ shift to 550nos/shift.
• Manpower reduciton in Scarp Handling System
• Monitoring OEE calculation for packing equipments, Monitoring OPE for IC plant
• Machine wise Down time data collection for analysis
• Analyzing breakdown of machine by applying analysis tool (PM analysis, FEMA, FTA, 4M-Analysis,
Why Why Analysis, WWBLA, and SMED).
• Master creation in PIMS Package and Uploading all downtime data to PIMS package Daily
• Conducting JH activities in model area, implementing JH activities in other area
• Coordinating PM Pillar to reduce the break down of the machines
• Implementing Kaizen with separate Task force in order to improve productivity & cost saving
• Conducting Training program for employees
• Assisting maintenance department to prevent the breakdown of machines by implementing TBM, PM, CBM, MP (for A class Equipments)
Achievements:
• Preparation of 3 model machines to JH step-3 standards resulting in improvement of productivity
• Increased MTBF of equipment’s up to 50%
• Decreased MTTR of equipment’s up to 30%
• Implemented more than 75 Kaizen in order to improve the productivity
• Won Third prize in zone level kaizen competition