TPM implementation at Son Hai Van company (Part 2)

Son Hai Van Co., Ltd. is an enterprise specializing in the production of high-grade paints serving the marine and industrial sectors such as epoxy paint, concrete floor paint, fireproof paint, heat-resistant silicate paint, etc, and many more other civil paint products to serve the needs of ship building and repair.

With the foundation of good practice 5S from 2018 and continuously maintained until now, Son Hai Van Co., Ltd. has decided to participate in the program of implementing TPM (Maintaining overall performance) with Autonomous maintenance pillars (AM) and Planned Maintenance (PM).

In order to strengthen the connection between the operator and the maintenance department, aiming to jointly manage and take care of the machine, TPM members have carried out a series of activities such as: Drafting machine operating instructions. crushing and pasting machine; building “One-point lessons” (OPL) on safety operating instructions; suspend TPM card when error is detected, etc.

Based on the self-managed maintenance pillar, a number of jobs were put on the daily list by the company’s officers and employees:

– Checking devices

– Perform minor maintenance operations

– Draw lines, make signboards, have numbered PL01, PL02, Vietnameseize name of electrical cabinet;

– Re-drafting operating instructions at the mill; thinner and paste machine;

– Record anomalies on TPM card and summarize the card number for each employee every month. At the end of the year, the company awarded prizes, recorded according to the number of TPM cards.

As for the planned Maintenance pillar, Mr. Nguyen Van Diep – Equipment management officer shared about the activities of the M&E team for this pillar:

– Prepare & monitor maintenance / repair plan. There are 12 sheets of monthly maintenance plan, of which in May, updated based on the results of April maintenance.

– Unexpected repair / troubleshooting. 36 problems classified into 2 groups of errors.

– Carry out maintenance / repair according to Plan. Train yourself on how to maintain the mill.

– Write Operating Procedures, One Point Lessons and Standards for Maintenance

– Equipment and components are strengthened to manage and report material replacement every quarter.

In addition, the Company also implements the Centralized Innovation (FI) pillar with the aim of offering solutions to ensure on-time delivery rates (limiting customer complaints about late deliveries). The company-focused improvement process started with an improvement team meeting: (1) forming an improvement team, announcing company leadership’s expected goals, (2) discussing observations, data related to losses; (3) analysis of ongoing losses and waste at a pilot stage (raw material grinding). There were 39 reasons proposed after the meeting, through which the improvement team classified these 39 causes into 7 core groups of causes; (4) 5 Why analysis and 4M analysis for these causes. The 4M analysis results helped the installation team come up with 5 innovative solutions for management methods. The above solutions do not cost or cost a very little investment. With the focus of the improvement group, the company recognized losses, proposed 5 groups of improvement solutions in the coming time, effectively reducing losses and wasting for the company and safety for employees.

TPM assessment results at the company show:

1) The overall equipment performance index (OEE) increased from 83% to 96%.

2) Some processes are renewed and guaranteed to comply with requirements (Operating instructions for the machine, Summary of cards, Management of spare supplies, reporting of replacement supplies, Error analysis procedure after performing current maintenance).

Based on the achievements of TPM implementation in 2019, Son Hai Van has set a target for 2020 on the percentage of employees participating in TPM activities within the scope of TPM implementation will reach 100%.

Productivity and Quality Office