Page 240 - TPM A Route to World-Class Performance

214 TPM-A Route to World-Class Pevfovmance

Derek Taylor comments: ’At each stage of the journey, WCS worked closely
with teams, managers and facilitators, the union and key contacts to promote
in-house ownership.’

Site-wide improvements made under TPM
Various improvements were made, including net annual cost savings for:
0 42 proactive TPM teams
TPM team activity boards
0 Each piece of equipment is labelled with the name of its team leader
and corresponding maintainer
Asset care routines for operators and maintainers on all equipment
0 Introduction of single-point lessons (SPLs) to offer a concise and easily
accessible training guide for processes or pieces of equipment
Computer systems that log unplanned events direct from the machine
computers to a central database
Training facility built and in-house training courses developed
CAN DO - Cleaning, Arrangement, Neatness, Discipline and Order -
adopted on the shopfloor, in the stores and in administration to provide
a world-class workplace as in 5Ss
0 Visual indicators on machines, for example, colour-coded dials marked
to show safe operating limits
Shadow board for tools
Disciplined quarterly TPM audit system with milestones and levels
0 Operators and maintainers involved in early design reviews before
acquiring new equipment (TPM for Design)
ATPM team was introduced in the maintenance stores which completely
revolutionized the stores system, ensuring that spare parts are always
readily available and providing foolproof systems for locating and logging
out items

People benefits

0 People development
Enhanced skills
0 Greater staff involvement
Improved morale - operators’ ideas are implemented with an acknowl-
edgement that engineers don’t always have the only or best answers
Improved trust and a more open relationship between operators and
maintainers and between teams working across different shifts
0 New identification of training needs through analysis of what people
do know versus what they could or should know - opportunity to
increase skills and knowledge
0 Improved communications
0 A more motivated workforce
0 A strong sense of ownership and pride in the workplace