Page 263 - TPM A Route to World-Class Performance

Case studies 237

- Wastesand
- gas emissions
- Kaizen/continuous improvement
- Attendance
- Customer returns
- Lost time accidents
- Injurious accidents
- Audit conformance
- Product conformance
- Mainpac reports
- Activityboards
Each team has an activity board covering subjects such as milestone activities,
for example schedule adherence oust in Time), key performance indicators,
training status, health and safety, today's quality actions and previous day's
conformance report by production, scrap and target.
0 Total Manufacturing Concept (TMC), A system whch pinpoints adions
for each machine, each month, under headings of Quality, Cost, Delivery
and People.
0 Quarterly housekeeping audits.
0 Shadow boards Each area now has shadow boards for storing tools in an
ordered and easily identifiable way.
0 TPM fm Design TPM for Design principles are applied when specifying
new machines and processes.

To keep abreast of such a variety of routines, the teams have to dedicate
substantial tune to TPM activities, as well as flexibility to ensure that a meeting
deferred is not a meeting abandoned. In spite of production pressures, TPM
team members recognize that they have to 'take time to save time'.

3.0 Benefits

TPM has both a direct and an indirect effect on a production system. The
direct effects are easier to assess and are directly quantifiable (see Table 11.1).
The indirect effects can be ascertained from more subjective measures,
such as morale and absenteeism levels, which show themselves as an increase
in the efficiency of the overall production system. Estimating cost savings
involves looking at a variety of factors, from labour and materials costs to
energy savings and increases in production capacity.
Indirect savings attributed to TPM include sharing of best practices, both
across the shifts and with the site in general, and TF'M teams solving problems
that have a beneficial effect on unrelated areas, e.g. improving stock control
systems.
The combination of indirect and direct effects at RHP Bearings Blackburn
generated major savings. Major site-wide benefits from TPM activity were
scored in the following areas: