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TPM PILLAR ASSIGNMENTS (June, 2012)

TO BE COMPLETED BY THE PILLAR TEAM MEMBERS


Autonomous Maintenance (Olukoya Ajayi):

1. Prepare AM vision, mission statement and objectives.


2. Prepare AM slogan.
3. Develop autonomous maintenance implementation plan showing machine
classification and timing for the AM steps up to end of 2015.
4. Identify AM pilot machine from machine classification.
5. Set pillar targets for three years for both pillar & pilot machine to include:
- Number of defect tags per employee per week
- Number of Before/After improvements
- Number of One Point Lessons
- Machine cleaning time KAI TARGETS (Direct
- AM training time targets)
- Volume per shift
- OEE
- Number of Breakdowns per shift
- Number of minor stops per shift KPI TARGETS
- % Defect and rework (Indirect targets)
- Number of safety incidents per year
6. Select another project (to be solved by using 10-step kaizen) of excessive
leakage or usage of consumption material
7. Prepare AM board layout.
8. Complete the AM pillar membership to be multifunctional

Planned Maintenance (Ram Kumar):

1. Prepare PM vision, mission statement and objectives.


2. Set pillar targets for three years to include:
- Number of unexpected stops greater than 10 minutes
- % operation time lost
- MTBF
- MTTR
- Lubricant consumption per ton of Pasta
- Spare parts inventory level
- Energy consumption / ton of output
- Maintenance Spending in Naira per tonnage of output
- TPM Savings
3. Develop PM Master Implementation plan.
4. Complete the PM pillar membership to be multifunctional
5. Prepare A5 size failure analysis form ASAP
6. Select a Zero failure pilot project
7. Select a focused area energy saving project
8. Commence the recording of breakdowns with form and start immediate
why why analysis on breakdowns. Develop improvement action plan
9. Give emphasis to support AM tag resolving activities
10.Subdivide plant to number of fitters and give numerical personal targets to
achieve for each area

Focused Improvement (Alimi Olumide):

1. Prepare FI vision, mission statement and objectives


2. Set pillar targets for three years
3. Develop FI master implementation plan
4. Categorize the site losses using the 16 major losses as guide
5. Complete a sample OEE calculation with the standardized losses for at least
two packing machines
6. Select pilot SMED project for product change over in Pasta line
7. Select Decreasing wrapper change time project
8. Obtain correct expense costing from accounts for one machine for a year
and bring correct measurement of OEE losses for same machine for the
same period. Get them ready for cost loss analysis workshop
9. Develop a table to show products versus production lines containing ideal
cycle times
10.Develop another table to show the volume to be produced per month per
product
11.From 9) and 10) derive a table which shows production line saturations (the
theoretical time calculated should be corrected by OEE)
12.Complete the FI pillar membership to be multifunctional

Quality Maintenance (Ada Amogu):

1. Prepare QM vision, mission statement and objectives


2. Set pillar targets for three years
3. Develop QM Master Implementation plan
4. Start capturing and properly recording all process and packing defects and
rework
5. Start capturing and properly recording consumer complaints
6. Develop a defect policy deployment for Pasta
7. Develop a quality improvement roadmap from the above
8. Start organizing daily quality meetings with production and maintenance
personnel on the shop floor
9. Launch a pilot figure 8 defect reduction project
10.Do a material balance analysis of Pasta operation
11.Complete the QM pillar membership to be multifunctional

Safety, Health and Environment (Peter Odion):

1. Prepare SHE vision, mission statement and objectives


2. Set pillar targets for three years
3. Develop SHE master implementation plan
4. Review site risk assessment
5. Develop negative map by using red dots in order to show all kinds of
accidents and risks for the last five years.
6. Select a pilot project area where red dots are most intensive.
7. Plan to take all different types of proactive actions.
8. Map and measure waste generation I a) absolute amount and b) per ton of
product sold
9. Complete the SHE pillar membership to be multifunctional

Early Management (Andrea Girolimetto):


1. Prepare EM vision, mission statement and objectives
2. Using the given training module, develop Golden Pasta early
management process flow showing details of all the stages
3. Customize the given early management problem list and fill for the Pasta
plant
4. Develop a Maintenance Prevention-MP form
5. Complete the EM pillar membership to be multifunctional

TPM in Administration (Joseph Adebambo):

1. Prepare pillar vision, mission statement and objectives


2. Set pillar targets for three years
3. Develop pillar master implementation plan
4. Prepare list of all offices including production offices
5. Arrange an office cleaning exercise on a weekend(or public holiday) using
set rules and standards
6. Select a pilot office for improvement
7. Prepare a tag for office anomalies
8. Make a site layout to show all stocks and showing stock type, weight, stock
days and Naira value

Training and Development (Sam Obukelihor):

1. Prepare pillar vision, mission statement and objectives


2. Set pillar targets for three years
3. Develop pillar master implementation plan
4. Develop an operator skill profile and conduct a skills gap analysis of one
operator, and hence determine the detail training topics.

General (Kingsley):

1. Set TPM targets (PQCDSMEI) for three years for Pasta and split to pillars.
Pillars to use given targets to develop own targets for same period

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