Application of TPM in a new product launching- a case of unilever Bangladesh

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.