Page 246 - TPM A Route to World-Class Performance

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plus the cost of repairs in terms of labour and spares. If you then look at the
fact that this product may be part of an urgent shipment, there are implications
for customer service. If we want to meet the customer’s deadline, then we
have to look at getting staff in at the weekend, plus using air instead of sea
freight. The costs just snowball.’
Liz also focuses on cost deployment, which highlights the cost of not
making things ’right first time’ (cost of quality). TPM’s six losses were top of
the hit list. The benefits of cost and quality deployment are:
0 As a motivator for teams
0 Teams are able to make financial decisions (empowerment)
TPM teams can speak senior management language (i.e. €s)
0 Focuses on costs

It5 the people that matter
TPM is often associated with people empowerment, and Adams has working
examples of this. Chris Rose continues: ”We have found that TPM teams are
responding directly to business requirements in terms of production - for
example, in finding ways to meet customer requests for amended packaging.
The team will look at trialling a solution or new way of working and then
report in to management to request the financing required to fully roll out the
improvements. Previously, capital expenditure requests were the sole remit
of management.”
The environment in which TPM thrives, along with the workers, is one of
flexibility and versatility. Jobs are developed away from previously rigid
roles. Operators, as opposed to electricians, now calibrate some machines.
This frees up the electricians to work at a more technical level, which in turn
enables proactive, instead of reactive, working to take place.
TPM teams also come up with best practice guidelines for each piece of
machinery. These are incorporated into training manuals and videos and
disseminated across all shifts.
TPM for Design principles are also applied to new machinery, through
involving the experience of the operators and maintainers, with minimum
OEE levels negotiated into the terms of purchase and commissioning.
TPM has benefited safety and environmental issues in a number of ways.
An element of the criticality assessment covers safety, and any improvement
in looking after the equipment will have knock-on benefits in this area.
Not least, it has helped raise awareness with regard to safety issues and
empowered those same workers to effect a cure or remedy with the help of
key contacts such as the Health and Safety Officer.

Benefits
Work is made easier by working smarter, not harder.
Better understanding of engineering and production problems.
0 Operators have a more in-depth understanding of the machine.