Page 264 - TPM A Route to World-Class Performance

238 TPM-A Route tu Would-Class Peufuvrnance

0 €400 000 running costs saved
0 Unit cost reduced by 21 per cent
0 Scrap reduced by 8 per cent
0 Attracting increased capital investment currently at 15 per cent of turnover
0 Customer returns reduced by 11 per cent
0 Increased customer satisfaction
0 Improved safety record
0 Environmental and quality awards
0 Improvement in staff morale

Table 11.1 Example of four TPM Teams
Direct TPM savings

Team Saving Main benefits porn:
Beach Boys E50 000 Set-up reduction
WRIST E20 000 Set-up reduction
DREAM €80 000 Cycle time reduction
Shiftnal €60 000 Cycle time reduction

Total E210 000

Shiffnal sphering machine
The Shiftnal, a 26-year-old sphering machine used for the production of a
range of larger castings, is one of the oldest machines at the plant.
The TPM team responsible for the Shiftnal has now developed a detailed
refurbishment plan, having almost completed the TPM cycle. Through the
implementation of TPM, the machine has been brought up to PUWER
(Provision and Use of Work Equipment Regulations) standard, with the use
of two button start, guarded off areas and asset care with a cleaning and
preventive maintenance schedule.
Other key improvements include:
Total cost saving OEE improved by 25 per cent. The team are now
targeting areas of poor OEE by product and problem type.
0 Cycle time improved by 6 per cent, equating to the production of
an extra sixteen castings per day with a potential sales value of over
E30 000. The improvement was implemented though the introduction
of a sphere position switch, costing just a few pounds.
Changeovers speeded up by the production of tool kits, so that all items
required for each casting type are readily available and labelled.
A variety of other time-saving methods have been put in place. For example,
to check the torque reading of the casting, the operator, Norman Jameson,
had to lift the heavy metal casting into a vice set upon the workbench. At