Award for TPM Excellence, Category B
THAI INDO KODSA CO., LTD.

1. Organization ProfileKordsa
In 1973 Kordsa, the leading manufacturer of industrial nylon and polyester yarn, tire cord
fabric and single end cord, was established as a subsidiary of Sabanci Holding. The map below
displays the business area of Kordsa

Thai Indo Kordsa
The company was founded in 1990 in Ayutthaya, Thailand as Thai Branta Mulia as theleading producer of Nylon 66 and Polyester tire cord fabrics in Thailand. In 2006, Thai Branta
Mulia became an integral part of Kordsa. Afterwards, Thai Branta Mulia was renamed to Thai
Indo Kordsa. As of 2021, the Thai shareholders holds 35.81% of Thai Indo Kordsa’s shares
whereas PT Indo Kordsa holds 64.19% of the shares. The company itself represents the imageof outstanding professionalism, highly qualified products, and holds overwhelming passion toperform with utmost efficiency which has made the company succeed to this day.
ProductThe Thai Indo Kordsa business line is based on the manufacturing of tire cord fabric are
made from Nylon 66 and Polyester, which are highly resistant to high temperatures, has highmodulus, low elongation, good dimensional stability, and low humidity absorption andshrinkage.

Tire Cord Fabric

Process
The Tire cord Fabric (TCF) production process starts from the Mill unit (Twisting andWeaving) in yarn preparation area. The Raw material preparation operator prepare the yarns
then Twisting operator load yarn to the twisting machines according to the production schedule.
After finished twisting process, twisted cords are doffed from twisting machine to pallet andstore in intermediate area. For weaving process, Creel loading operator load twisted cord toweaving creel then the weaver operator weave greige fabric and doff the greige fabric fromweaving machine. Last process is Dipping process that dipping greige fabric with dipping
solution, drying and treat with tension. The flow of production process can be seen in below
figure.

Twisted CordYarn

Greige fabricDipped fabric2. Milestone on the Journey to Manufacturing Excellence
Since beginning 2016, TPM meaning was the road for us to walk on to change our mindsets
to handle all issues to make our business and social life easier and more efficient.
Since the first day of TPM implementation in the company, up until now, as Thai IndoKordsa Employees, from every discipline and all level, we are walking all together andworking hard to have better safety performance, high quality products and services, including
lower breakdowns and with less waste.
For sure, continuous improvement required to put in practice lots of Kaizen every day inyour activities and you can realize it with happy and dedicated employees. 2022 was the yearfor Thai Indo Kordsa to get “Great Place to Work” certificate. On top of this wonderfulsuccess, we also reached 8.1 million hours free injury days in our all operations. While ourproduct and service quality are increasing in parallel customer complaint numbers aredecreasing.
We are aware that this is not the end for us. The life is ongoing and changing very fast! So,
the challenges in the world and around us will not stop. In a such competitive environment,
we will keep our dedication and energy level at highest level to learn from our TPM consultant
and each other in the company to add values our activities hence add value our products andservices to keep our customers, employees, business partners, communities and for sure ourshareholders.
3. Benefits Achieved
Below are tangible benefits on key business results.
Category

Index

Unit

Benchmark
2016

Actual Status
2023

PP

OEE
Number of breakdowns
MTBF Twisting Weaving DippingMTTR Twisting Weaving Dipping
Customer complaints
In-line defect rate
Rework
Production Lead time
Accident
Number of Employee
Suggestions%
Breakdowns/ year

70.8
416

71.6
232

2,971
613
165

4,250
1,110
223

Number/year%%Days
Cases/ year

5.2
3.12.06
0.58
1.66
30.2
0

1.6
1.6
2.0
3
0.48
0.92
26.3
0

Number/year

258965PP
QQQDSM

HourHourIntangible benefits to company- Changing mindset of machine breakdown- Enhanced ownership of employees- Enhanced teamwork- Improvement in house keeping- Improvement in knowledge- Improvement in skills of operators and technicians- Improvement in motivation of improvement studies- Improvement in machine conditions

4. Key to our Manufacturing Excellence
The key to Manufacturing Excellence is continuous improvement in all areas with all
employees in the company.
5. Contact
Thai Indo Kordsa Co., Ltd.
1/61 Moo 5 Rojana Industrial
ParkKhanham Subdistrict Uthai District
Ayutthaya 13210 Thailand
Tel. + 66 35 330221-9
Fax + 66 35 330230