Page 262 - TPM A Route to World-Class Performance

236 TPM-A Route to World-Class Performance

Operators were sent off to climb over their machines and log problems through
a detailed condition appraisal, to establish a foundation for future TPM
improvements.
TPM was piloted on two key machines, the PGM core making machine in
the foundry and the Shiftnal sphering machine in the machine shop, using a
detailed seven-step TPM implementation programme:

1 Collection and calculation of Overall Equipment Effectiveness (OEE)
data
2 Assessing the six losses
3 Criticality assessment and condition appraisal
4 Risk assessment
5 Refurbishment plan
6 Asset care and best practice routines
7 Regular review for problem solving

TPM is currently implemented at the site by nine different TPM equipment
teams, involving 60 per cent of the workforce.
TPM is applied to machines of all ages - from new to 30 years old -
ensuring that older machinery is brought up to modern specification and
newer machinery is kept in ’as-new’ condition. TPM can also help the running
of new machines in other ways. For example, the new shot blast machine
runs at an OEE of just 60 per cent due to hold-ups in other parts of the
foundry process. TPM has identified the external bottlenecks to allow the
machine to work to its full potential.
The cross-functional teams include operators, maintainers, quality
technicians and group leaders. These core teams are supported by Kevin
O’Sullivan and can also draw on the skills of key contacts from other areas.
For example, Quality Associate and Toolmaker, Alan Shaw, works for four
teams as a key contact because of his specialist skills.
Each team has worked hard to develop a standard TPM routine for its
respective machine, using the following methods:
Autonomous Maintenance System (AMs) boards
These mobile boards show a schematic of the machine which the operator
then tags with labels to show losses affecting availability, performance
and quality. The labels are then used to generate an agenda for TPM
team meetings.
TPM step notices Notices on each machine illustrate its current stage in
the seven-step process.
Mainpac database An in-house database is used to gather machine
performance data and calculate OEE. The system is also used to assess
the over-maintaining of machinery, where OEE results are consistently
good but maintenance levels high.
Key performance indicators Each team assesses itself according to progress
and improvements in the following areas: