Abstract:
This thesis is related to the application of TPM in an innovation project and this is based
on a case study of Unilever Bangladesh Limited. And for this a specific project is chosen
“Local (onshore) manufacturing of conditioner”.
The objective of this thesis work is to analyze TPM activities during launch phase of an
innovation project and to find out how the TPM activities are giving benefit to a
manufacturing organization. For justification of this objective some KPI’s were selected:
on time, innovation ramp up, vertical start up and OEE).
During this project implementation activity few TPM tools were applied as a part of early
management process which helped smooth execution of the project. To find out different
activities and share roles and responsibilities for individuals a details network was done
with Gantt chart. To identify different losses, problems and find out a solution -a 4M
analysis was done by studying the whole process. Again a FMEA process was done to
identify the probable failure of the project, and accordingly necessary solutions were kept
ready to face the problem. A detail WWBLA analysis was also done to know the root
cause of a specific problem/issue. This problem was occurring frequently and tried to find
out a logical solution by using WWBLA. As TPM is already established in Unilever
Bangladesh, during the study of this innovation project other established activities (as a
part of TPM) impacts were also checked; such as: Planned maintenance (PM), planned
inspection schedule (PIS) etc. Safety is always first- so to ensure proper safety for this
innovation project detail risks assessment was done using different safety risk assessment
tools, like: PHA, HAZOP, THA and SOP etc. All those risk assessments were done
during different stages of the projects starting from very initial stage. Beside those as a
part of early management process some other activities were also done, like: trials, MOD
(to ensure proper change management), One point lesson (share key information to all).
After completion of the project the different KPI’s were measured which were as per
target. And the results are: on time start of the project, Innovation ramp up 95.27%,
vertical start up- 24 hours, OEE-87%. This analytical data is also proving that TPM is
giving benefit in terms of Productivity, Quality, Cost, Safety health and environment,
Moral, Innovation and Delivery in case of a new project launching.
