Page 250 - TPM A Route to World-Class Performance

224 TPM-A Route to World-Class Performance

checklists, best practice routines, asset care procedures and problem-solving
techniques, which have increased the Overall Equipment Effectiveness (OEE)
in all four pilot project areas.
STL, Gerry Scanlan, observes:

The project has given the team a lot of personal satisfaction and
a great deal of hard work went into it. Many Best Practices have
been developed which have been rolled out to the other two
shifts that are working back to back with ours.
This cascading of information from shift to shift, and ultimately
having the agreement of all four shifts, is vital to the success of
the CI Initiative.

MOL pumps
PO6 is one of the three turbine-driven pumps used on the Main Oil Line
(MOL) system. These have all become less prone to unplanned shutdowns.
P06’s best fit OEE is now at 50 per cent as at end December, up from 6 per
cent in May 1997.
Howard Dickson, MOL Team Co-ordinator, comments:
PO6 was the worst of the three pumps. A Critical Assessment
highlighted a pile of smaller jobs that needed to go through the
maintenance system. We had to establish a fault-reporting system
as a framework to get the jobs done - all have now been actioned
or scheduled.
Some jobs are just too big and so needed onshore support. This
opened up communication lines with the engineers and vendors.
Everyone now knows in whose area things belong. We also had
some very good discussions among the techs themselves -before
this hands-on team-based approach, we just hadn’t been aware
of the problems other disciplines were having.
Howard concludes: ’The structure of the 9-step improvement programme
helps you do it the correct way, even though it can seem a bit heavy.’

Seawater injection
Two excellent results were obtained in this area. The OEE has risen from 45
per cent to 90 per cent and the corrosion control performance has risen from
42 per cent to 89 per cent.

Hydro c y don es
The main breakthrough for the hydrocyclone team was in identifying the
problem with the inlet quality from the separators. As a result, both Bank A
and Bank B hydrocyclone facilities greatly increased their OEE rates - Bank
A from 40 per cent to 55 per cent over the year, and Bank B up to 80 per cent
from 10 per cent - an excellent result.