Award for TPM Excellence, Category A

                                                           

Our MD, Mr.S.Ravichandran and our CMO  Mr.HT.Rajan sharing the Happy Moments with

                                                             Coimbatore Site Team

 

Why TPM in TTK PRESTIGE LIMITED?

 

In today’s industrial scenario huge losses/wastage occur in the manufacturing workplaces. This waste is due to many reasons such as due to operators, maintenance personal, process, tooling problems and non-availability of components in time etc.

 

Other forms of waste includes idle machines, idle manpower, break down machine, rejected parts, operating the machines below the rated speed, start up losses etc are all examples of waste. The quality related waste are of significant importance as they matter the company in terms of time, material and the hard earned reputation of the company.

 

Zero oriented concepts such as zero tolerance for waste, defects, break down and zero accidents are becoming a pre-requisite in the manufacturing industry.

 

In this situation, we did SWOT Analysis to understand our strengths and weakness. Subsequently we understood that TPM is the best tool for our business improvement because many industries across the world successfully implemented to address the above said problems.

 

Objectives of TPM:

TPM was introduced to achieve the following Objectives.

a)      Achieve Zero Accidents

b)      Achieve Zero Defects

c)      Achieve Zero Break downs / Losses.

d)      Involve people in all levels of organization

e)      Form Cross- functional Team for identifying new ideas for the implementation and sustenance and Self-Maintenance across all the workplaces.

 

Our Coimbatore Plant was selected to implement TPM by the Top Management.

 

About Coimbatore Plant:

Coimbatore Plant started in the year 2006 for manufacturing Aluminium Outer Lid Pressure Cookers with annual capacity of 3 lacs. Workforce was new from agricultural background with low educational qualification. Continuous training and strong commitment improved our production capacity to 6 lacs cookers in the year 2010-11.

 

Declaration followed by TPM Kick off was done in Dec 2010. A modern facility was built utilizing the existing and new equipments. The initial plan was to increase the capacity to 15 lacs per annum by CAPEX / Infrastructure development.

Gorgeous View of the facility

Plant Lay Out

Thanks to TPM Practices and Knowledge, we adopted single piece flow mechanism in forming line with automations, thus improving our manufacturing capacity to 30 lacs Cookers per Annum. We are certified by ISO 9001:2008 QMS and Pressure Equipment Directive (PED) for CE Marking. Thin staff function supported by corporate team in all aspects is a key factor in our plant.

             

Assembly Section

                                               

 Milestones during the Journey towards Manufacturing Excellence:

To achieve Manufacturing Excellence, we took drive from our Vision and Mission and released TPM Quality Policy which motivates our commitment towards our goal. TPM Quality Policy encompasses all our regulatory requirements and Quality Management Systems.

Our Slogan “War On Waste” is the personification of our tireless journey to achieve zero losses.

   

Mile Stones  of Coimbatore Site   à

 

 

Benefits Achieved:

TPM implementation helped us to make sustainable improvements in each and every aspects of our workplace operations. Our team is now excited by the opportunity to make improvements individually and in teams for enhanced business performance.

According to the rapid changes in the business scenario, skilled and knowledgeable work forces are required in order to achieve the future challenging Targets. The TPM practices encourage our employees to improve their professional developments with many learnings and growth opportunities.

Now, the employees have higher morale, career satisfaction and motivation which help to increase the Productivity.

 

 

Tangible Benefits:

 

Following are the tangible benefits achieved in terms of PQCDSM (i.e)

 

P à Productivity

Q à Quality

C à Cost

D à Delivery

S à Safety and

M à Morale

 

Intangible Benefits:

1.  Cultural Change is evidenced among employees.

2.  Shop floor became clean, dry & pleasant to work.

3.  Improved Ownership and Accountability.

4.  Visual display and Visual Controls on machines has improved across the plant.

5.  Safe, Hygienic work place.

6.  Excellent Team work.

7.  TPM became the way of our life.

 

Some of the memorable photographs are below:

 

TPM Award  for Excellence                                        

         Category “ A “  à

         

 

 

 

 Future Plan:

  • Involving supply chain management to reduce the inventory further for improving the turnover and profits.
  • Involving Tool Room to provide tools right first time and to improve the flexibility in production to respond our customers in a shorter period.
  • Implementing Innovative / breakthrough kaizens across the workplace to achieve Zero Losses.
  • Up keeping the momentum of all our employees by maintaining the positive work culture.
  • Develop Subject Matter Experts from the shop floor for JH and PM topics.
  • Challenge Excellence in Consistency Award in year 2016.