Implementation of TPM at Flexographic Printing Area

Core Focus on 5S, EHS and OEE

Abstract

Environment, Health and Safety (EHS)

Total Productive Maintenance(TPM) provides a comprehensive, life

cycle approach to equipment management that minimizes equipment
failure, production defects and accidents. We applied TPM following
the areas of 5S,EHS & OEE.
5S is basically a workplace management methodology which helps for
improving working environment, human capabilities and thereby
productivity.
EHS methodology is used to achieve and sustain zero accidents and to
create healthy and pleasant workplace environment by taking multiple
actions .
OEE is a metric that identifies the percentage of planned production
time that is truly productive.

EHS is an essential pillar of TPM, which aims to achieve and sustain zero
accidents and to create healthy and pleasant workplace environment by
making equipment safer, preventing pollution, improving employees health
and by improving working environment.

EHS Trends
120

105

100
80
80
60

45

40

30

20

Objectives

30

25

0
LTA/LTI

Environmental
Incidents

Fire Incidents

First Aids

Past Trends

45

To reduce waste
To Improved efficiency
To use work space effectively
To improve safety
Better, more committed employees
To improve quality

Targets

Hazards Reported

Hazards Closed

Pending Hazards

Targets Achieved

Before | After

Before | After

Methodology
5S methodology contains total 5 steps which
are listed below:
i. Seiri (Sorting): Take out all the un-necessary
items and throw them away.
ii. Seiton (Set in order): Everything should be
set in order at its specified place.
iii. Seiso (Shine): Clean everything to create an
impeccable place and inspect for defects.
iv. Seiketsu (Standardize): Maintain a high
level of housekeeping all the time.
v. Shitsuke (Sustain): Develop good
housekeeping habits through lot of practice.

Overall Equipment Effectiveness (OEE)

OEE is a hierarchy of metrics used to evaluate how effectively a
manufacturing operation is utilized. It was developed to support TPM by
accurately tracking progress towards achieving Perfect Production.

EHS methodology contains several steps and

varies according to workplace environment, we
applied EHS at Packages by certain steps as
shown in figure 1.

OEE = Availability Performance Quality

OEE Trends
80%
75%

80.00%

Figure 1:EHS Methodology

70.00%

60.00%

5S

53%

50.00%

40.00%

Its a workplace management technique which provides the basis for

implantation of TPM. It helps us to reduce waste and hence increase
efficiency and quality.

35.00%

30.00%

20.00%
10%

12%
9.00%

10.00%

7%

6%

4%

6%

3%

0.00%
Availability loss

Performance loss
Past trends

5S Trends

5s Audit Radar
Chart

Quality loss
Targets

OEE

Target Achieved

OEE

Sort

25
20

80%
80%
70%

76%

60%

58%

15
10

Sustain

60%

50%

53%

38%
40%

35.00%

Set in
order

30%

9.00%

30%
3%
20%
10%

11%
5.00%

8%
2.87% 1.50% 1.90%

0%
Downtime

Wastage
Past Trends

Injury
Targets

Audit

Achieved

Standar
dize
Score(After)

Shine
Score(Before)
Availability loss

Before
Before ||After
After

Performance loss

Quality loss

OEE

Before| After
Conclusions

Reduced downtime up to 3% (from 11% to 8%)

Reduced Injuries up to 20% (from 58% to 38% )
Improved 5S audit up to 16% (from 60% to 76%)
Reduced hazards report up to 60 (from 105 to 45)
Improved OEE up to 22% (from 53% to 75%)

Group Members

References

Mubashir Iftikhar
Muhammad Hassan
Rafay Ahmed Tariq
Muhammad Umair

1. Business Unit Flexographic Printing Department Packages Limited

(BUFP).
2. Industrial Performance Department Packages Limited.
3. Consumer Products Development Department Packages Limited.

(2012-IM-55)
(2012-IM-56)
(2012-IM-54)
(2012-IM-45)

Department of Industrial & Manufacturing Engineering ,UET Lahore