OTPM -Material fucntions activities

Support to Production & Material Office efficiency

> Support to Production :-
P - Line Stoppages due to 1) Nonavailability of material , 2) Loss due to defective piece.
Q - CC/PPM due to Inhouse Vendor quality.
C- Purchase cost & Logistic cost.
D - Lead time for new development & 100 % Delivery adherence.
S - Recycling of materials, not creating environmental Hazardous.
E - Disposal of Scrap like Plastics , ETP Liquid.

> Material Office efficiency :-
P - Office productivity, No of. people deploy to carryout activities, First time right.
Q - Quality of work , No error & Rework.
C- Cost of Stationary, Cost of Travelling, Cost of other trasactions & communication.
D - Time response to process - Purchase order & to make material GRN..
S - Protection Soft data, Data loss, Hacking of Network security.

Losses In Office Area

Losses realted to Office Function areas are :

1.Value Loss - Over dated work or procedure that is unused or rarely used
2.Processing loss - Repetition, error, rework, adjustment processes
3.Accuracy loss - Correctness, sureness.
4.Speed and timing loss - Time required for the activities.
5.Idle loss - Waiting for instruction, movement of papers , searching for files.
6.Communication loss - Transmission of information, communication and response.
7.Cost loss – Including in areas such as Procurement, accounts, marketing, sales leading to high inventories.
8.Decision Making Loss - Taking more time for decision of signing cheque, activities plan etc.
9.quipment breakdown Loss - Office area printer, system breakdown etc.

These are some identified losses related to Office area, you can identified various losses related to your office functions. These losses will be totally different from the TPM 16 Losses because that losses are related to your manufacturing areas & these are related to office areas.

Three Pillar Approach in Office TPM

Basically Office TPM starts with 5S :
1S : Seiri : Sort Out
In IS activity, all unwanted should be disposed to the Red tag zone(area) with Red tag.
2S : Seiton : Systematic arrangement.
In 2S activity, The things which are wanted, required should be kept in specified location , systematic in order, easy to access & with identification.
3S : Seiso : Shine
In 3S activity, you should clean the workplace & the things which are required.
4S : Siketsu :Standardization :
In 4S activity, what you have done in 1S,2S,3S should be sustained, for that standard is to be made.
5S : Sitsuke : Self Discipline
In 4S activity, Standard that you have made in 4S should be followed with descipline. If Descipline not followed , sustainance impossible.
So, 4S & 5S is only for sustenance of 1S, 2S & 3S.
After doing 1S,2S & 3S in Office areas, immediately standards for the cleaning, Inspection of office area should be made & that standard should be followed with descipline.

After 5S implementation, Start JIshu Hozen, Education & Training & After that Kobetsu Kaizen activities.

Education & Training for Understanding the office Functions procedures, systems etc.

Three Pillar included in Office TPM Pillar are
1. Jishu Hozen -Autonomous Maintenance
2. Kobetsu Kaizen - Individual Improvement
3. Education & Training

Aim, Objective & Background

Aim :

To understand the relationship of office activity and production activity and achieve customer delight & zero functional losses by creation of efficient office functions.

Objective :

-Continuously improving Productivity, Efficiency in the Administrative functions.
-Identify & eliminate losses.
-Reduce costs
-Raise levels of customer satisfaction
-Improve office working environment.

Background :

-High Inventory.
-No Synchronization of function.
-No Work Procedures.
-Procedural troubles
-Payment Default