It's a Case study Presentation about the Past Brand Hindustan Lever limited which is now HUL (Unilever) and the concept about TPM (Total Productive Management)

1. CASE STUDY ON:
HINDUSTAN LEVER LIMITED
(SUBJECT: PRODUCTIONS AND OPERATIONS MANAGEMENT)
Prepared by :
• Asit Dholakia
• & Team

2. HISTORY
 Hindustan Vanaspati Manufacturing, first Indian
subsidiary set up in 1931
 Lever Brothers India Limited set up in 1933
 United Traders Limited set up in 1935
 All 3 companies merged to form HLL in 1956
 The Anglo-Dutch company Unilever owns a majority
stake in Hindustan Unilever Limited.
(owns a 52% majority stake.)
 Renamed In June 2007 as Hindustan Unilever Ltd.

3. BRAND PORTFOLIO….
Food
Brands
Home
Care
Brands
Personal
Care
Brands
Water

4. FOOD
BRANDS
Jams,
squash,
ketchup
&
Bread
Flour
& Salt
Coffee
Tea
Soup
Ice
cream

5. HOME CARE
BRANDS

6. PERSONAL CARE
BRANDS

7. WATER
• “As Safe As Boiled Water”
• Doesn’t need gas, electricity, or continuous water
supply
• Water clear, odorless and tasty
• No residual chlorine
• Free home demonstrations

8. Hindustan
unilever ltd
Personal wash
Lux, lifebuoy, dove
Pears, rexona, breeze,
Laundry
Surf excel
Wheel
Skin care
Fair & lovely
Ponds
Vaseline
Hair care
Sun silk
Clinic
Oral care
Pepsodent
close-up
Deodorants
Axe
Rexona
Color cosmetics lakme
ayurvedic Ayush

9. PLANTS ACCLAIMED WITH AWARD
 Japan Institute of Plant Maintenance [JIPM] Honored its JIPM
excellence awards on Hindustan Lever Limited’s (HLL) Plants
 Sumerpur, Chhindwara, Yavatmal [Personal products]
 Silvassa [Personal Products]

10. PLANTS PRODUCTS & PRODUCTION CAPACITY
 Dadra & Amli Villages Near Silvassa are home to the two
personal Products Factories Of HLL
 Dadra unit Has Production Capacity Of 5000 tones per
annum (tpa) and the Amli unit has a capacity of 18000 tpa.
 The products Manufactured in these factories include:
 fairness creams(fair & lovely),
 Lotions, Shampoos
 (Clinic All Clear, Sunsilk-
 both bottles & sachets),
 Deodorants, Talcs (denim) &
 Toothpaste (Pepsodent)

11. WORN-OUT MACHINE PARTS
 At the silvassa Factories of HLL, the Worn out Machine parts
are not tossed out to the trash like other factories does.
 The Workers collect These failed parts Carefully.
 Formal Records of such parts are Maintained by the Workers
And these parts are stored in a specially Created ‘Museum’

12. AT SILVASSA FACTORIES OF HLL:-
• WORN-OUT MACHINE PART
• FORMAL RECORDS
• STORED AT MUSEUM

13. PURPOSE SERVED BY THESE PART ARE
• UNDERSTAND WRONG THINGS
• MODIFICATION OF DESIGNING
• REDUCE CHANGEOVER TIME
• DISPLAY BOARD SYSTEM

14. DISPLAY BOARD SYSTEM
• A CROSS
• FIND TRAINER
IN CASE OF NEW MACHINE

15. TOTAL PRODUCTIVE MAINTENANCE
 Maintenance management is planning,
organizing, and controlling maintenance
activities such that the overall maintenance
cost is the minimum.

16. Why we need TPM ?
 The major objectives of the TPM are
listed as under :
1. Avoid wastage in quickly changing
environment.
2. Reduce Cost of Manufacturing
3. Goods send to Customers must be
“ non – defective”

17. TYPES OF MAINTENANCE
 Breakdown maintenance
 Preventive maintenance

18. Benefits of TPM:
 Less breakdowns.
 Life of equipment increases.
 Production cost can be minimize.
 Qualities of production can be improve.
 Reducing accidents.
 Higher confidence level among the workers.
 Rectify customers complaints.
 Keep the work place clean, neat and attractive.

19. TPM COSTS AND BENEFITS OVER THE PAST
THREE YEARS AT HLL
Manufacturing site Investment
(Rs million)
Benefits
(Rs million)
Silvasa 15.00 210.00
Chhindwara 8.00 24.00
Yavatmal 6.00 60.00
Orai 4.50 60.00
Raipura 4.20 62.00
Mangalore 6.20 111.00
Daman 10.0 139.00
sumerpur 2.00 23.00

20. 1. Autonomous maintenance.
2. Individual improvement.
3. Planned maintenances.
4. Quality maintenance.
5. Development management.
6. Education and training.
7. Safety, health & development.
8. TPM in office.
THE EIGHT PILLAR OF TPM

21. FOUR LEVELS
 To the TPM factory organizational structure at
the HLL, there is mainly 4 levels are working
which are,
 At top the corporate TPM steering committee
headed by HR director.
 At the next level there is a group comprising the
technical head of HLL, corporate quality
assurance and the TPM head and factory Head.

22. CONTINUE….
 Below this level pillar heads are working.
 At the lowest level there are TPM circle composed
by workers and headed by an officer of HLL. Each
circle has unique name and identity.

23. COMPETITORS
 Colgate Palmolive
 P & G
 Nestle
 Marico
 Nirma
 Dabur

24. CONCLUSION
 TPM technique is very beneficial
to the Company.
 Enthused with the Results of
TPM implementation, Hindustan
Lever Limited management has
decided to implement this
initiative at every strategic site
and all new factories, including
Uniliver Factories in the region.