Page 241 - TPM A Route to World-Class Performance

Case studies 215

Business benefits

Improved OEE, thus releasing the lnherent productive capacity
Improved working conditions
Machine problems addressed instead of Lived with, leading to increased
efficiency
Improved quality - product and processes
More effective return on capital employed
Greater reliability of machinery, and so less reactive and expensive
maintenance
Better able to meet and exceed customer expectations
Able to predict areas of wear in machinery
Safer working environment
Prevention of breakdowns
Prolonged life cycle of equipment

4.0 Continuous improvement and TPM

Overall
3M Aycliffe uses TPM as the means of providing an opportunity to all staff to
contribute to the programme of continuous improvement.
Continuous improvement for 3M Aycliffe also means continuous assessment.
A stringent TPM audit system is in place whereby each improvement zone is
assessed according to two rmlestones under which sit four levels of achievement.
Each improvement zone is identified with a plaque clearly showing the level
it has attained. In order to move through the four levels, each team has to
hold gains of the last level and wdl, therefore, be reassessed on previous
levels.
Bottom-up and top-down audits are completed quarterly and the results
are then compared to preset benchmarks. The Aycliffe site also runs an annual
recognition scheme, with targets set for OEE results and team level status.

TPM in the stores
The stores at 3M Aychffe, which holds accessories and spare parts for all
machines, also underwent a TF'M-driven overhaul two years ago. The changes
that were made as a result have completely revolutionized the stores system,
ensuring that spare parts are always readily available and providing foolproof
systems for locating and logging out items.
The stores now has a precisely ordered shelving system by part manufacturer,
a database search facility and single-point lessons for locating items, how to
book out items, and returning items for repairs.
The classic six losses have been modified to apply to the stores system, to
enable a stores OEE to be generated, so that efficiency can better be assessed.