Customer

Tan Tien

Tan Tien Plastic Packaging Joint Stock Company (Tapack) is a leading company in Vietnam in the production of flexible packaging.

TST Consulting Company provides Lean - TPM implementation consulting for Tan Tien company.

AM implementation consulting for the production departments: Printing, Laminating - Blowing, Bag Making - Roll Splitting, Plate Making.
PM implementation consulting for the Mechanical and Electrical department..
FI implementation consulting for the entire factory.

1- Progress: After 2 years to deployed LeanTPM:

- AM: Passed step 3.

- PM: Passed step 2.

- Continuous improvement to eliminate waste:

Create Loss Map for each factory
FI - Focused Improvement: Factory Director level is responsible.
Sub -Theme improvement: Manager level is responsible.
Small kaizen: Each employee is responsible for implementation & will implement according to the AM program.

The improvement of eliminating Waste has been included in the company's system

Select a topic - Implement/monitor - Report - Update/issue new standards.
Each topic is implemented for a maximum of 3 months
At the same time, each department selects at least: 1 FI & 1 Sub-theme to implement.

After evaluating the results of the "LeanTPM Consulting" contract No. 02, the B.O.D of Tan Tien Plastic Packaging and TST Consulting Company agreed to sign the "LeanTPM Consulting" contract No. 03 for the next phase:

Increase efficiency in product quality.
Build a Centerline system - Operating parameter monitoring system: Equipment/process/system.

2- Efficiency:

- Equipment: Time of failure (Data from April to October 2013):

Printing Factory: Failure decreased by 57.7% compared to 2012.
Laminating Factory: Failure decreased by 22.3% compared to 2012.
Blowing Factory: Failure decreased by 78% compared to 2012.
Roll Splitting Factory: Failure decreased by 80% compared to 2012.
Bag Making Factory: Failure decreased by 32% compared to 2012.
Plate Making Factory: Failure decreased by 7% compared to 2012.

- Material loss, Quality:

Some factories decreased insignificantly, the most prominent is the Bag Making Factory: Quality errors decreased by 26%.

- Productivity:

Printing Factory: Production increased by 9.15%
Laminating Factory: OEE increased by 4.5%
Blowing Factory: OEE increased 10%.
Roll Splitting Factory: Output increased by 15.5%
Bag Making Factory: Output increased by 21.58%.

- Maintenance costs: (From January to October 2013):

Total maintenance costs from January to October 2013 decreased by 56% compared to the same period in 2012.

- Outstanding Kaizen improvements:

Printing Factory: Improved Troley carts so that solvents are not lost for weekly ink cart cleaning.
Laminating Factory: Increased Tâ€™ram roller life, saving hundreds of millions of dong in re-engraving each month.
Roll Splitting Factory: Improved machine downtime.
Bag Making Factory: Improving online corner cutting knives for standing bags: Sunlight, Omo, Comfort... bringing in billions of VND in profit each year.

- Focused improvement (FI):

Plate Making Factory + Printing Factory: "Medium Reduction" Project: Medium ratio in OPP, PET reduced by 8.4% and 6.5% respectively.
Printing Factory: "Reducing ink supply rate" Project. Ink inventory reduced by 22.26%. Saving billions of VND each year thanks to the design to reduce the volume of ink tray from 18 kg to 12 kg.
Laminating Factory: "Increasing machine speed, reducing corrugated errors" Project. Some key machine lines such as Rotomec, Huitong, Nord, the speed of some product lines has increased from 16% to 50%. Corrugated errors reduced by 95% compared to the original.
Blowing Factory: "Reduce Blowing Scrap" Project: Blowing scrap has been reduced by about 20% compared to the original.
Bag Making Factory: "Reduce bag bending errors, increase output on product line: Ajinomoto MSG". OEE has increased by 11% compared to the original, bag bending errors have been significantly reduced and are within the customer's allowable threshold.

- People:

Operator: Able to find/handle defects, create OPL to share experiences, perform simple equipment maintenance tasks: CIL, master equipment.
Maintenance staff: Able to divide work into groups, perform preventive maintenance. Damage is analyzed, costs are managed, spare parts inventory is managed by min/max.

BlueScope Lysaght

Jinyu

TaTa

Tata Coffee is a part of the Tata Group. Founded by Jamsetji Tata in 1868, the Tata group is a global enterprise, headquartered in India, comprising over 100 independent operating companies. The Group operates across enterprise and social sectors in 6 continents, with a mission 'To improve the quality of life of the communities we serve globally, through long-term stakeholder value creation based on Leadership with Trust'.

TST Consulting Company is honored to receive the trust of TaTa VN's B.O.D in supporting TaTa VN in implementing LeanTPM into the company's production/business activities, in order to maximize resources - produce products at the lowest cost.

Up to date, TATA VN and TST have signed their third LeanTPM consulting contract.

Starprint

Starprint Packaging Printing Company has chosen TST Consulting Company as a partner to implement "Lean-TPM", implementing Lean - TPM activities in the entire factory of Starprint Thailand in Vietnam (Amata Industrial Park, Lot 104/4-1, Amata 2-4, Long Binh Ward, Bien Hoa City, Dong Nai).

- Consulting on AM implementation for the production block.

- Consulting on PM implementation for the Mechanical and Electrical Department.

- Consulting on FI implementation (Focused Improvement), to eliminate/minimize waste and maximize cost efficiency in production.

After about 2 years of TST consulting on LeanTPM implementation for Starprint Printing Joint Stock Company (Thailand), we have evaluated the implementation progress, achieved results and reached an agreement: Starprint continues to sign consulting contract No. 03: "Consulting on LeanTPM implementation" for the entire factory for the fiscal year 2016-2017.

Some results:

- "Box broken - Gluing" error decreased from 0.092% to 0.046%.

- "Diecuting - Die-cut" error reduced from 0.2% => 0.1%.

- Reduce SMED time on UV Rolland machine from 40 minutes to 30 minutes.

- Reduce SMED time on N1050FH, N1050SE, N1050SE machines from 50 minutes => 40 minutes.

- Improve "Reduce C&A and ARC production people at 3-knife stapling & cutting stage

* Before: C&A: 5 people/3000 pcs => After: 4 people/3,500 pcs

* Before: ARC: 4 people/3000 pcs => After: 3 people/4,000 pcs

Kumho VN

The TPM program implemented at Kumho Tire VN has completed step 3, in the coming time, AM step 4 will continue to be implemented.

- In the roadmap for implementing TPM steps 1,2,3: Kumho VN's Board of Directors has selected TST Consulting Company to support with training contracts 01,02,03: "Technical training on Operation - Installation - Maintenance" 6 basic modules create working points for the factory's operators and maintenance staff.

1- Technical installation - operation - maintenance of the Pneumatic system.

2- Technical installation - operation - maintenance of the Hydraulic system.

3- Technical installation - operation - maintenance of the Belt drive.

4- Technical installation - operation - maintenance of the Motor/Gearbox.

5- Technical installation - operation - maintenance of the Bearing.

6- Tightening Techniques: Bolts, Nuts, Keys,...

7- Basic Electrical Techniques and Electrical Safety.

- After a period of cooperation and support, the Board of Directors of Kumho Tire VN has trusted the capabilities of TST Consulting Company, we agreed to continue signing training contract No. 04: "Training AM experts step 4" for Kumho Tire VN employees located in My Phuoc III Industrial Park, Binh Duong, Vietnam.

Kumho Vietnam is a member company of the 7th largest Kumho Asiana Group in Korea with nearly 40 member companies. Kumho Asiana has invested in Vietnam since 1993 and now has 7 member companies operating in Vietnam.

Kumho tire factory was inaugurated in March 2008 in Binh Duong (My Phuoc III Industrial Park) with a total investment capital of 200 million USD and current capacity of 3 million 150 thousand units per year. In the coming time, the company will invest in phase 2 to increase capacity to 6.3 million units per year.

Kumho Tires has 8 manufacturing plants around the world: 3 in Korea, 4 in China and 1 in Vietnam located in Binh Duong province specializing in manufacturing tires for passenger cars (PCR), light trucks (LTR) and SUVs.

Olam VN

Saigon Trapao

Joint Stock Sai Gon Packaging Company (Japan) was established in 1995, producing and supply many types of plastic packages, products are soft plastic packages, multiple layer laminates, boxes and rollers (Supply for package factory used in modern package technology)â€¦This technology of printing & joining Polyme layers (BOPP,PET,PA, CEL, MCPP, MPET, PP, PE, LLDPE, CPP, RETORTâ€¦), it is different to package technology of PET bottle ( Food & drinkâ€¦), plastic trays, boxes (PET, PE, PP, CERO-FOAMâ€¦), many type of vases, bottle, plastic tankâ€¦ and also different to single layer packages (shopping), sewing PP packagesâ€¦sell at market.

In 2002, Saigon Trapaco invested in expanding the factory and upgrading equipment at VÄ©nh Lá»™c Industry Zone. With new factory built and modern equipment, technology...,helping to growing up and long term plan of the company.

On this journey, both TST Consultant Company and Joint Stock Sai Gon Packaging Company (Saigon Trapaco) agreed on the contract of â€œLean- TPM consultantâ€ to deploy LEAN- TPM culture in the factory at VÄ©nh Lá»™c Industry Zone, BÃ¬nh ChÃ¡nh District, HCM City:

-5S.

- AM for operation team.

- PM (Plan maintenance) for maintenance room.

- FI (Focus Improvement)/Loss, objective to cut the loss and maximize efficiency of production.

Outspan Café VN

Outspan cafe VN started using TPM Consulting service of TST Consulting Company in 2015-2016 with consulting contract No. 01: "TPM implementation consulting".

TST will consult Outspan cafe's factory (Nhat Chanh Industrial Park, Ben Luc District, Long An Province) to apply Total Productive Maintenance program in its production activities to reduce waste and enhance competitiveness by improving product quality at the most competitive price.

- After the end of consulting contract No. 01, the two parties evaluated the implementation progress, the achieved results and reached an agreement: Outspan cafe continued to use TPM Consulting services of TST company and signed consulting contract No. 02: "TPM implementation consulting" phase 2

- After the end of consulting contract No. 02, Outspan cafe and TST continued to sign consulting contract No. 03: "TPM implementation consulting" phase 2018-2019.

- After the end of consulting contract No. 03, Outspan cafe and TST continued to sign consulting contract No. 04: "TPM implementation consulting" phase 2019-2020.

Marico VN

Marico VN is one of leading company producing and distributing customer goods like fabric & homecare, beauty care and food products. With many well known brand names leading Viet Nam market: X-men, X-men for Boss, Dr.men...Marico VN curently is one of 3 leading companies of haircare products at Viet Nam and be ranking as one of FMCG companies has fastest growing market share at Viet Nam.

To leverage operation â€˜s capability of the factory, Marico VN proposed TST Consultant Company to be a great partner to provide the technical hand on training to employees:

1- Tool installation - Operation â€“ Maintenance Pneumatic system.

2- Tool installation - Operation â€“ Maintenance Belt Transmission

3- Tool installation - Operation â€“ Maintenance Motor/Gear box.

4- Tool installation - Operation â€“ Maintenance Bearing.

5- Tool installation - Operation â€“ Maintenance Fastener.

6- Total Productive Maintenance