PROJECT REPORT ON TOTAL PRODUCTIVE MAINTENANCE-AN EVALUATIVE STUDY| MBASIKKIM MANIPAL UNIVERSITYLC CODE:249PROJECT PERIOD:JAN-JUNE’2012| |
ASHOKE KUMAR RUJ|
STEEL AUTHORITY OF INDIA LTD|
Objective: The study aims at churning out the existing maintenance Practices in Durgapur Steel Plant,a sister unit of Steel Authority Of India Ltd(SAIL) and project to modern Total Maintenance Practices(TPM) with all its pros and cons discussed for the achievement Of Higher Productivity.
3.Analysis of Performance
5.Discussion with HOS and other Maintenance People
1.Steel Authority Of India Ltd
2.Durgapur Steel Plant
3.Steel Melting Shop
4.Continuous Casting Plant
Total Maintenance Practice is a coordinated Maintenance Practices among the personnel of a production unit. It aims to bring a culture of unity and ownership. It reduces the gap in the activity of operation and maintenance people. In today’s cut throat completion across the industries coupled with shortage of manpower, it is very much essential to devise a strategy that will help implement best maintenance practice so that production can be maximized. We need to adopt dynamic maintenance practices in its true sense for our survival with higher ABP target achievement.
Here, a study is presented to understand TPM and its effectiveness as a whole. Many industries have been benefitted by implementation of this principle.
Maintenance is the integral part of production process and sustainable production is not possible without a proper and all-round maintenance practices. In DSP, being an integrated steel maker with many world class products, an established maintenance practice is already in vogue. But, if TPM gets implemented, it will be another achievement to bring in the latest Maintenance Practices. People are the greatest asset of any industry. The aim should be to keep the unity and ownership of each employee towards a unique goal-to make their organization a sustainable and profitable entity.
TABLE OF CONTENTS
Chapter1: Definition Of TPM (6-7) Principles 7
Overall equipment Effectiveness(OEE) (19-23)
Company Overview of SAIL(29-35)
Overview of Durgapur Steel Plant(36-70)
Survey On key Parameters (72-87)
Shop equipment Breakdowns & Analysis(93-109) Recommendations (110)
(DEFINITION OF TOTAL PRODUCTIVE MAINTENANCE)
TPM is a unique Japanese philosophy, which has been developed based on the productive maintenance concepts and methodologies. This concept was first introduced by M/s Nippon Denso Co Ltd. of Japan, a supplier of M/s Toyota Motor Company,Japan in the year 1971. Total productive maintenance is an innovative approach to maintenance that optimizes equipment effectiveness, eliminates breakdowns and promotes autonomous maintenance by operators through day-to-day activities involving total workforce. TPM definition (1)
A company-wide team-based effort to build quality into equipment and to improve overall equipment effectiveness 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
TPM definition (2)
TPM combines the traditionally American...