at
Tinplate Company of
India
Introduction
Tinplate Company of India Limited a Tata Company
An Introduction
TCIL is the largest indigenous producer of tin coated and tin free steel
sheets in India
Having 35-40% market share
The industry leader for more than 90 years
Headquartered in Kolkata, the Companys Works is located at
Jamshedpur, Jharkhand
Presently 11 offices in India and a distribution network with 16
stocking points
TCIL Works presently has two Electrolytic Tinning Lines (ETLs) and
Cold Rolling Mills (CRMs)
The Company is in the business of manufacturing and supplying
reliable, cost-effective, value-added tin mill products
It manufactures various grades of electrolytic tinplates, tin-free steel
sheets and Full Hard Cold Rolled Sheets (FHCR) used for metal
packaging
The Decision
TPM (Total Productive Maintenance)
What is TPM?
To
markedly
increase
production while, at the
same
time,
increasing
employee morale and job
satisfaction
Objectives of TPM
Achieve
Zero
Defects,
Zero
Breakdown and Zero accidents in all
functional areas of the organization
Involve people at all levels of
organization
Form different teams to reduce
defects and drive Self Maintenance
TPM @ TCIL
TCIL Speak TPM Policy
We are committed to adopt TPM through the participation of all
our employees. Our aim is to achieve zero failure, zero defects
and zero accidents. We shall achieve this by creating a clean
and pleasant work place through teamwork and committed
employees.
Direct benefits of TPM
Increase productivity and OEE (Overall
equipment efficiency) by 1.5 or 2 times
Rectify customer complaints
Reduce the manufacturing cost by 30%
Satisfy the customers needs by 100 %
(Delivering the right quantity at the right time,
in the required quality)
Reduce wastage in fast changing environments
Reduce accidents
Follow pollution control measures
Process Structure
Identify the process structure for any two stages of
manufacture of a product of the chosen business
Electrolytic Tinplating
Process
Cold
Rolled
Steel Coil
Uncoiling
Alkaline
Cleaning
Rinsing
Pickling
Rinsing
Electroplating
with tin
Drying
Brightening
by Reflow
unit
Passivation
Oiling
Shearing
Classifier
Packing
Despatch
Tin Electroplating
Soak
Clean
Electro
-clean
Plate
Rinse
Rinse
Acid
Rinse
Hot
Rinse
Bright
Dip
Chro
mate
Rinse
Dry
The State-of-the-Art new combination line with Electrolytic Tinning & Tin Free Steel production facility
is one of the main reasons that enabled TCIL to achieve this target for capacity expansion in the short
time frame
TCIL has a wide range of product offerings both in coil & sheet form for the discerning customers,
primarily in the growing domestic and international markets and facilitate in consolidating its
undisputed status as the leader in the domestic market and emerge as a world class regional player
As previously discussed TPM is also one of the strategy used by TCIL to improve their capacity by
increasing productivity by 1.5 to 2 times and decreasing their manufacturing cost by 30%
Products
List at least two variants of the above product
Operations Planning
Briefly describe how Operations Planning could be adapted
to the above identified process structures
Aggregate Planning
OUTPUTS
ELECTROLYTIC TINPLATE
(tonnes)
2010-2011
2,23,090
2,01,823
2011-2012
2,41,182
2,64,403
2012-2013
2,93,128
3,23,426
2013-2014
3,09,812
3,35,833
CUSTOMERS:
Tinplates product open top sanitary cans in the form of finished goods are serviced
to Tayo rolls limited, The Tata pigments limited and Tata steel international
(Singapore) Pt. Limited
Interdependence
STEEL
STEEL
As you can see in the above structure, steel is used twice in the process
Usage of steel is a dependent variable because it is used in the production of finished
goods
Planning Horizon
MRP Processing
Inventory Management
Model
To take advantage of economies of scale and smoothen production requirements,
TCIL uses the EPQ Model
Economic production quantity (EPQ) is the quantity of a product that should be
manufactured in a single batch so as to minimize the total cost that includes setup
costs for the machines and inventory holding costs
Production is done in batches or lots
Raw Materials Used
Steel and Hot rolled coils procured from Tata Steel
Acid for electroplating
Packaging box
Spares
Inventory Management
Lead Time
The key raw material involved in steel and hot rolled coil which is procured from
Tata Steel
The lead time usually is between 12-15 days
Inventory (safety stock) must be planned in accordance with the lead time
To effectively decrease the lead time for raw materials, TCIL commissioned its
state-of-the-art 120,000 tonnes per annum Cold Rolling Mill having the benefit of
synergy with Tata Steel
Inventory Counting System
TCIL could emply the Perpetual Inventory System wherein removals from
inventory continuously, thus monitoring current levels of each item
Universal Bar Code to be created and labeled on each product variant to monitor
products inventory level
Thank You!!!
References