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.

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

45
30
25

Objectives

20
4

0
LTA/LTI

Environmental Incidents

Fire Incidents

First Aids
Past Trends

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%
80.00%

Figure 1:EHS Methodology

75%

70.00%

60.00%
53%

5S

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

Quality loss
Past trends

5s Audit Radar Chart

5S Trends

Targets

OEE

Target Achieved

OEE

Sort

25
20

80%
76%

80%

15

35.00%

70%
60%

58%

10

Sustain

60%

Set in
order

53%

50%

38%
40%
30%

9.00%

30%
3%
20%
11%
10%

5.00%

8%
2.87% 1.50% 1.90%

Standardiz
e

0%
Downtime

Wastage
Past Trends

Injury
Targets

Shine

Audit

Achieved

Score(After)

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% )