TPM ACTIVITIES MIXER 2

MOHD RASDAN

GOODYEAR MALAYSIA BERHAD

MALAYSIA MIX#2 TPM

(RELIABILITY IMPROVEMENT)

Mixer 2 TPM Organization Chart - 2015

Yazid YaacobAdvisor

Mohd RasdanTPM Leader

RozaidiQ-Tech Engineer (Mixing)

Sharul NizamTeam Leader C9

SubramaniamTeam Leader C9

Mohd NazriTeam Leader C9

HanafiahBanbury Specialist C10

Wardi MohtarEngineer

Zahari IbrahimEngineer

Nor AziziEng. Specialist

Abdul HalimConstruction Member

Ahmad ZakiBCA Manager

MALAYSIA PLANT - DEFECT CARD BOARD, CLEANING TOOLS BOX AND TPM INFORMATION BOARD

TPM ACTIVITIES (CB DAYBIN)

CARBON BLACK DAYBIN LEAKS ELIMINATED

AND DAILY CHECK LIST SYSTEM DEVELOPED.

Before After

TPM ACTIVITIES (CB DAYBIN)

Before After

DAYBIN CARBON BLACK LEAKS ELIMINATED

AND DAILY CHECK LIST SYSTEM DEVELOPED&IMPLEMENTED AND ALL UNNECESSARY IDLE Eqs REMOVED.

TPM ACTIVITIES ( GENERAL VIEW DAYBIN AREA)

Before After

TPM ACTIVITIES ( DAYBIN SILICA AREA)

Before After

LEAKS SOURCES ELIMINATED WITH RELIABLE

ENGINEERING DESIGN, TPM STANDARDIZATION

&CHECK LIST IMPLEMENTED.

Before After

CHARGE AND DROP DOOR GATE LEAKS REPAIRED AND AREA STANDARDIZED

TPM ACTIVITIES ( MAIN MIXER)

TPM ACTIVITIES ( MAIN MIXER BODY)

Before After

CHARGE AND DROP DOOR GATE LEAKS REPAIRED AND AREA STANDARDIZED

TPM ACTIVITIES (OIL CABINET)

NEW OIL CABINET TO IMPROVE MACHINE RELIABILITY AND TO IMPROVE LEAK

Before After

PROBLEM ANALYZED (SILANIC TANK LEAK)

RESULT AFTER IMPLEMENTATION (BANBURY % PERFECT TURN)

June 2014 -Banbury % Perfect Turn = 69.1% (Before TPM Implementation)

May 2015 – Banbury % Perfect Turn = 84.07% (After TPM Implementation)

RESULT AFTER IMPLEMENTATION (MIXER 2 MACHINE BREAKDOWN 2014/2015)

Initial Cleaning

TPM Level 1

TPM Level 2

RESULT AFTER IMPLEMENTATION (MIXER 2 CB WEIGHING IMPROVEMENT )

CB WEIGHING CONSISTENT AFTER TPM IMPLEMENTATION

RESULT AFTER IMPLEMENTATION (MIXER 2 OIL WEIGHING IMPROVEMENT )

OIL WEIGHING CONSISTENT AFTER TPM IMPLEMENTATION

RESULT AFTER IMPLEMENTATION (MIXER 2 IDLE TIME IMPROVEMENT )

Mixer Daily average Batch increased from 329 / day to 436 /day after TPM

Progress in 8 months

$-

$ 200

$ 400

$ 600

$ 800

$ 1,000

$ 1,200

$ 1,400

$ 1,600

Top 5 Loss CategoryTotal by category

ZERO LOSS ANALYSIS- LOSS STRATIFICATION

-

$ 500

$ 1,000

$ 1,500

$ 2,000

$ 2,500

Top 5 losses by department

IMPACT OF TPM ACTIVITY TO OTHER LOSS CATEGORY

Q3'14 Q4'14 Q1'15

Misc Unknown stop 41 32 28

2.57.5

12.517.522.527.532.537.542.5

$ , K

Q3'14 Q4'14 Q1'15

Rework 46 44 34.57

2.57.5

12.517.522.527.532.537.542.547.5

$ , K

Q3'14 Q4'14 Q1'15

Breakdown Maintenance 33.5 82.6 14.496

5

15

25

35

45

55

65

75

85

$ , K

Reliability Improvement Activities / Spare Part Replacement

OBSERVATION:TPM activity give good impact to other loss category