Page 47 - TPM A Route to World-Class Performance

28 TPM-A Route to World-Class Performance

Some examples of benefits from TPM
Case A: chemical processing plant

0 By-product output constrained by capacity
5 per cent increase in OEE to 90 per cent
Worth €400 000 in increased contribution per annum
Case B: manufacturing machining cell TPM pilot project

0 OEE increased from 40 per cent to 72 per cent over six months
Best of best OEE of 92 per cent
0 47 per cent reduction in set-up and changeover times
0 100 hours per month liberated via TPM improvements
Additional manufacturing potential worth €48 000 per year by bringing
subcontracted off-load work in-house

Case C: automotive manufacturer
15-year-old wheel balancer
0 Average OEE before TPM = 45 per cent
0 Cost of refurbishment = €8000
0 Each 1 per cent improvement of OEE = €694 per annum
OEE achieved after three months = 69 per cent
0 Worth €17 000 per annum

Case D: polymer-based material producer
0 Production line from raw material input to bulk reels
0 Reference period OEE = 77 per cent
Consistent achievement of best of best OEE = 82 per cent
Value of achievement = €250 000 per annum in reduced costs
0 One-off cost of improvements = €1000

Case E: cement plant
0 Weigh feeder mechanism unreliability
0 Reference period OEE = 71 per cent
0 Best of best OEE achievement = 82 per cent
0 Worth €35 000 in energy savings per annum
0 Other TPM pilot improvements saved €300 000 per annum, plus avoidance
of capital expenditure of €115 000
Case F: offshore oil platform with declining reservoir
After two years of using TPM principles:

October 1997 achieved longest production run without shutdown since
1994
Gas lift now at greater than 90 per cent efficiency compared to 40 per
cent in 1995 and 60 per cent in 1996