PU CELL REF. NO.

Activity in
KK JH

New Paint Shop Cell 04 NPS\F-06\PM\C2\TT\090

QM PM HSE OTPM

Loss : L8 PM Kaizen Idea :

DM E&T

KAIZEN SHEET
Common size Bench Mark 97240 Target 44200 Start date 30.01.06 Finish date 15.02.06 Team Members : J D Nikam, P.K.Borkar. Benefits in P Q

TPM in

Kaizen Theme : To reduce spares inventory cost on ASU 04 fan & motor pulleys & belts. Problem/Present Status : Pulley sizes of ASU 04 fans of different size than that of ASU 01, 02 & 03 Before Sketch

Countermeasure : Replaced ASU # 04 Fan & motor pulleys with standard pulley, same as ASU 01,02 & 03.

After Sketch

1.

Saving in electrical energy 30792 units per year.

Sustainance Plan :
S.N. 1 Activity
Belt replacement

Resp JDN JDN

Frequency 1.5 year Monthly

Remarks

V Belt Pulley Analysis : High Spares inventory cost

Cost in Rs

V Belt Pulley
Result :
SPC 5000 belt Inventory cost

Belt tension checking

Horizontal Deployment :
S.N. 1 2 Area Resp Target Date Status

Separate spare pulleys/belt set need to be maintained for ASU 04 Pulley/belt of ASU 04 of different size than that of ASU 01,02 & 03.

100000
97240

75000 50000 25000 44200

Key word :- Different size

IMPR/TPM/F 01 Rev. 02 : Effective date 25.06.2005

Before

After
TPM - Nashik Plant

Saving calculation
Fan 01 Value Fan RPM Pulley diameter driver Pulley diameter driven V-belt Average Current (amps) KWH Units/day Units/Year Rs per year Total Net saving Rs Fan 02 Before After Before After replacement replacement replacement replacement 690 692 689.0 693 410 325 410.0 325 810 640 810.0 640 SPC 5600 SPC 5000 SPC 5600 SPC 5000 184.5 179 186 181.5 119.35 115.80 120.32 117.41 2029.01 1968.52 2045.50 1996.02 568122.27 551186.38 572741.15 558884.51 1914572.06 1857498.10 1930137.69 1883440.81 57073.96 46696.88 103770.84

PU CELL REF. NO. Activity in

KK JH

New Paint Shop NPS/F-06/PM/401

Loss : PM Kaizen Idea :

KAIZEN SHEET
Low evapouration rate Bench Mark Target Start date 01.04.05 Finish date 01.05.05 Team Members : P. K. Borkar, V. G. Ugale

TPM in

QM

PM

HSE

OTPM

DM

E&T

Kaizen Theme : To reduce the lubrication cost on process conveyor

Countermeasure : Use of low vapourisation rate lubrication oil.

Problem/Present Status : High lubrication cost on process conveyor and buffer chains. Yellowish stain marks oberved on insides of oven. Before After

OKS 352/2

Rocol chain guard 230

Benefits in P Q C D S M 1 Lubrication frequency reduced from weekly to monthly 2 Cleaning time of oven reduced by 8 manhours during deep cleaning activity.

Parameter Base Oil Base Oil viscosity Evapouration rate Chain wetness Carbonisation of oil GI panels insides oven

Value Not known 40 deg 220 cst 100 deg 9 cst 5 % every hour 07 days Yes Yellowish stains

Parameter Base Oil Base Oil Viscosity Evapourisation rate Chain wetness Carbonisation of oil GI panels insides oven

Value Synthetic ester 40 deg 398 cst 100 deg 29.2 cst 0.3% per hour 20 days No traces observed. No stains observed

Sustainance Plan :
Frequency Resp S.N. Activity 1 Check lubrication Cell leader weekly oil level 2 Remarks

Analysis : High lubrication cost on Sealer Oven conveyor High lubrication oil consumption High lubrication frequency High evapouration rate of lubrication oil Key word :- High vapourisation rate.
IMPR/TPM/F 01 Rev. 02 : Effective date 25.06.2005

Result :
Cost per year per conveyor

Horizontal Deployment : 268950 178920

S.N. 1 2 Area All process conveyors Resp cell leader Target Date 6-Mar Status Open

Rs

305000 205000 105000 5000

Before

After

TPM - Nashik Plant

PU : CELL : REF. NO. : Activity in KK JH Kaizen Theme :

New Paintshop NPS/04/39

Loss :

Breakdown

KAIZEN SHEET
Kaizen Idea : Arrangement for re-using pump by-pass water

TPM in
Bench Mark 6 breakdown/year Target 0 breakdown 7-Nov-04 Start date 12-Nov-04 Finish date Team Members :

PM

QM

OTPM

E&T

SHE

IFC

To eliminate breakdown on Paint stripping pump.

P. K. Borkar, A. M. Khond
Problem / Present Status : Before Sketch

Counter Measure : Connecting by-pass water to tank

Benefits in P, Q, C, D, S, M

C&D

Feed water By-pass water Spray lance water

After Sketch

1) 96 manhours saving/year Feed water 2) Spares cost saved 1.2 lac/year By-pass water Spray lance water 3) Water saving 15000 m3/year. (Rs saved 1.87 Lac/year)

Overhead tank

Waste water tank

Analysis :

To spray lance

Waste water tank

Results
Breakdown incidences 06

To spray lance
Horizontal Deployment : Nil

Paint stripping pump not working Discharge ventil and sleeve broken Heavy vibration and knocking in pump head

Cavitation of pump due to entrapped air in feed water Feed water line directly connected to plant supply line

0 F04

Nov 04

Mar 05

TPM Secretariat - Nasik

PU CELL REF. NO. Activity in

KK JH

New Paint Shop Cell-02 NPS\F-06\PM\C2\

QM PM HSE OTPM

Loss : Energy Kaizen Idea :

DM E&T

KAIZEN SHEET
Efficient motor.

TPM in

Kaizen Theme : To reduce energy consumption on Surfacer Oven circulation fans. Problem/Present Status : High power consumption on Hot Air Circulation fan

Bench Mark 119819 Electical units per year Target 60000 Electrical units per year Countermeasure : Start date 10.04.05 To change 45kw motor to 37kw motor.(Heat up 01, Holding Finish date 20.05.05 01 and Holding 02 circulation fans.) Team Members : V. G. Ugale P. K. Borkar. Benefits in P Q C D S M

Before Sketch

After Sketch

1. 2.

Elimination of Soft starter 03 nos. Saving in cash outflow Rs 1.00 lac Pm time reduction by 30 minutes per month due tobetter mountings of motor.

3,61,363
Electrical units/year

2,01370
Electrical units/year
S.N. 1 2

Sustainance Plan :
Activity Check motor current Resp cell 02 Frequency Monthly Remarks

Analysis :
High power consumption at Surfacer oven ciruclation fan

Result :
1500000

Savings

Horizontal Deployment :
S.N. 1 Area Sealer oven Heat up fan Sealer oven holding fan Resp Cell 02 Cell 02 Target Date May'06 May'06 Status Motor to be ordered Motor to be ordered

Fan Motor drawing higher current High power required to deliver required output.

Less overall efficiency of blower/motor.

500000 Before After

Key word :- Inefficient equipment

TPM - Nashik Plant

units

1000000

Holding 02
Motor capacity RPM Flow rate Head Average current KWH KWH per day Rs per day Rs per Year KWH per year 45 KW 2910 150 m3/hr 35 mtr 37.27 24.11 433.98 1462.51 409504.17 121514.59 Motor capacity RPM Flow rate Head Average current KWH KWH per day Rs per day Rs per Year KWH per year 37 KW 1465 150 m3/hr 37 mtr 20.13 13.02 234.40 789.92 221178.40 65631.57

Holding 01
Motor capacity RPM Discharge Average current KWH KWH per day Rs per day Rs per Year KWH per year 45 KW 1440 45000 m3/hr 37.27 24.43 439.74 1481.92 414938.66 123127.20 Motor capacity RPM Discharge Average current KWH KWH per day Rs per day Rs per Year KWH per year 37 KW 1440 45000m3/hr 20.13 13.54 243.72 821.34 229974.19 68241.60

Unit Rs

Heat UP 01
Motor capacity RPM Flow rate Head Average current KWH KWH per day Rs per day Rs per Year KWH per year 45 KW 2910 150 m3/hr 35 mtr 35.80 23.16 416.86 1404.83 393352.54 116721.82 Motor capacity RPM Flow rate Head Average current KWH KWH per day Rs per day Rs per Year KWH per year 37 KW 1465 150 m3/hr 37 mtr 20.60 13.33 239.87 808.37 226342.52 67163.95

361363.61

201037.13

160326.49

Before

After

361364 1217795

201037 677495

641305.9433

Saving Per Year ( Rs. In Lacs)

Sr 1 2 3

Area Electrical Energy LPG Other

In Lacs)

Saving / Year ( In Lac) 52.3 37.19 9.65