Page 247 - TPM A Route to World-Class Performance

Case studies 221

0 There is more cost awareness, not only of improvements in OEE, but
also of material costs. Workers are therefore more conscientious and
focused about waste.

Quotable quote

TPM has enabled people to develop skills that they didn’t know
they had.
Chris Rose

4.0 Team focus

Volpak bagging machine
The Volpak machine packs 120 bags of sweets every minute and was the
focus of one of Adams’ three pilot studies. The machine was part of the ’New
technology’ introduced into the factory over the past few years and had been
giving problems with quality and availability, partly due to the new type of
bag it was handling. Through collecting OEE data, assessing the six losses
and setting improvement priorities, dramatic improvements in performance
were made.
A 1 per cent improvement in performance on the Volpak is equivalent to
f35 000 in annual cost savings. In just three months, a series of improvements
resulted in the OEE leaping from 69 per cent to 78 per cent, giving €210 000
of cost avoidance and €105 000 of actual savings per annum based on an
original estimated and planned OEE for the nezo machine of 75 per cent.
Finance was then able to incorporate a target OEE improvement of 80 per
cent, giving a further saving of €70 000, into the budget for the following
year.

GD wrapping machine
When a reel of foil sweet wrappers ran out, it took approximately 4 minutes
to change the reel, with a loss of 50 wrappers and an average of 22 reel
changes per shift.
The TPM team responsible for the machine looked at an electronic heat-
impulse foil splicer, an improvement which led to L16 220 in cost savings for
the factory.

5.0 The future for TPM
The future objectives for TPM are to:

1 Reduce material usage.
2 Integrate TPM fully into the Adams culture.