Page 138 - TPM A Route to World-Class Performance

Applying the TPM improvement plan 117

0 produce an implementation plan to improve the equipment
reliability.

Background
Merlin Gun Technology has the following characteristics:
0 The company makes welding guns and welding tips.
0 Most of the volume is in welding tips.
The co'mpany experiences pressure from customers to produce in small
batches.
0 The company is expanding into further export markets.
0 Department 50 is recognized as the main bottleneck.
The company organization is shown in Figure 6.1.

Department 50
Department 50 makes the most popular welding tips. It has always been the
bottleneck department.
The department produces basically three types of tip (Figure 6.2):

e The 5020, a flat-head tip produced in two operations
The 5031, a tip with one angled face produced by three operations
* The 5042, a pointed tip with two angled faces produced in %our operations
There are three machines:
0 The LlOl computer numerically controlled (CNC) lathe
The M201 CNC Bridgeport Interact milling machine
The M202 Denford Easimill3 milling machine

The machine operating data are shown in Figure 6.3. It should be noted
that the times have been developed by the planners based on experience. The
machines should be capable of the following cycle times:

Managing

Maintenance Production Ordering
Manager Manager Procedure Control
I
I I I I
Dept Dept Dept Despatch
40 50 60
Figure 6.1 Merlin Gun Technology: organization