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5S-TPM

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Rameshbabu R

The document outlines a 10 step roadmap for 5S and Total Productive Maintenance (TPM) activities including daily plant rounds and action planning, sorting and arranging materials, marking walkways, visual displays, cleaning and shining, forming TPM pillars, and implementing autonomous maintenance over three steps. It also provides before and after photos of 5S activities in various areas like the finished goods floor, engineering stores, and office that show benefits of removing unwanted items and identifying unused materials, including identifying over 551 barrels totaling 75 tons of previously unidentified materials worth around 50 lakh rupees.

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Road Map for the activities 5S/TPM Activity 1 - Plant round / observations - Daily activity Activity 2 - Action Plan for the observations Daily activity Activity 3 - Sorting / Material arrangements Activity 4 - 5S gang way marking Activity 5 - Visual display Activity 6 - Cleaning / shining - Daily activity Activity 7 - TPM pillar formation Activity 8 - Autonomous Maintenance - step -1 Activity 9 - Autonomous Maintenance - step -2 Activity 10 - Autonomous Maintenance - step -3
5S Activity BEFORE AND AFTER PICS
5S Activity BEFORE AND AFTER PICS
5S Activity BEFORE AND AFTER PICS
5S Activity BEFORE AND AFTER PICS
5S Activity BEFORE AND AFTER PICS
5S Activity BEFORE AND AFTER PICS
5S Activity BEFORE AND AFTER PICS
View of FG floor after 5S arrangement
ENGINEERING STORES AFTER 5S Activity
OFFICE AFTER 5S RE-ARRANGEMENT ACTIVITY
1S & 2S benefits Removal of unwanted Items Identified the locked Cash by 1S & 2S Activity alone.
Unidentified and unused Materials details Unidentified / unused materials stored in the barrels are tested and Identified for usage. Total no. of Barrels 551 = 75T / approx. value Rs. 50 lakh Consumed in the month of Jul14 170 barrels = 23T / Value Rs. 16.78 lakh Stock for consumption Sep14 to Nov14 168 barrels = 24T Other plant transfer 14 barrels = 2.4T R&D test & confirmation 31 barrels = 5.3T Not usable 159 barrels = 24T FG/ SFG /D3 not usable & Packing materials not usable identified and separated from the usable materials.

More Related Content

5S-TPM

  • 1. Road Map for the activities 5S/TPM Activity 1 - Plant round / observations - Daily activity Activity 2 - Action Plan for the observations Daily activity Activity 3 - Sorting / Material arrangements Activity 4 - 5S gang way marking Activity 5 - Visual display Activity 6 - Cleaning / shining - Daily activity Activity 7 - TPM pillar formation Activity 8 - Autonomous Maintenance - step -1 Activity 9 - Autonomous Maintenance - step -2 Activity 10 - Autonomous Maintenance - step -3
  • 2. 5S Activity BEFORE AND AFTER PICS
  • 3. 5S Activity BEFORE AND AFTER PICS
  • 4. 5S Activity BEFORE AND AFTER PICS
  • 5. 5S Activity BEFORE AND AFTER PICS
  • 6. 5S Activity BEFORE AND AFTER PICS
  • 7. 5S Activity BEFORE AND AFTER PICS
  • 8. 5S Activity BEFORE AND AFTER PICS
  • 9. View of FG floor after 5S arrangement
  • 11. OFFICE AFTER 5S RE-ARRANGEMENT ACTIVITY
  • 12. 1S & 2S benefits Removal of unwanted Items Identified the locked Cash by 1S & 2S Activity alone.
  • 13. Unidentified and unused Materials details Unidentified / unused materials stored in the barrels are tested and Identified for usage. Total no. of Barrels 551 = 75T / approx. value Rs. 50 lakh Consumed in the month of Jul14 170 barrels = 23T / Value Rs. 16.78 lakh Stock for consumption Sep14 to Nov14 168 barrels = 24T Other plant transfer 14 barrels = 2.4T R&D test & confirmation 31 barrels = 5.3T Not usable 159 barrels = 24T FG/ SFG /D3 not usable & Packing materials not usable identified and separated from the usable materials.