It is our
Continuous
Improvement
System
Founded in TPM
What is World Class Manufacturing?
/2
What is TPM ?
TPM = WCM
4
External recognition for excellence
JIPM Total Productive Maintenance Awards
Developing Plants TPM Level 1 TPM Level 2 TPM Level 3
Advanced
TPM Award levels { Excellence Consistency Special Special World Class
The award system judges the results of a plants TPM activities. On average,
it takes about 10 years to go from the first to final level.
/5
WCM Journey
2015
2012 JIPM World
JIPM Advanced Class Award
2010 Special Award
JIPM Special
2008 Award
JIPM
Consistency
2005 Award
Theres no limit
JIPM
Excellence for our improvements
Award
2001
Kick off
WCM Principles
/7
Innovation and Kaizen
WCM approach to gain the competitive edge
Competitive
Innovation advantage
- Big jumps
- Big investments
- Top-down
approach
Kaizen
Gradual,continuous improvement
TIME
WCM basic principles
/9
Our Mission
HOW ?
People
Processes
Organization
Our Strategy
Develop People
-Training
-Coaching
-Empowering people for self learn
Develop Processes
-Standardize and align methods and tools
-Transfer WCM knowledge sharing best practices
Develop Organization
-Promote WCM people integration
-Keep WCM community alive
/ 11
What is a Loss?
Something we do that doesnt add any additional value
to the final customers product
It is often perceived as inevitable
It can be eliminated ... for the most part
RAW MATERIAL $
LOSS/WASTE
$ TIME/MATERIAL
Non value add
/ 12
What is a Loss specifically ?
It is the difference between the current situation and the ideal situation
Ideal Level
Loss
Current Situation
Loss
Deployment!
Main
Loss
Losses
Main
Loss How to eat the
elephant?
6.5%
Breakdow ns
Losses and repairs
(21)
47.6% Planned
Maintenance
22.5% (28)
Speed losses
Other stops
(23,25,26,27)
Set-up time
(12)
EE 55.1%
52.4%
17
Print - deployment of set up time
Losses Printer 2003 Set up time deployment FP2003 Set up frequency FP 2003
Set up losses Printer 2003
0.3% 6.0% 3.8%
4.0%
Other losses 7%
5.1% 5.4% 6.8%
6.5%
Breakdow ns 8.6%
and repairs
(21) 17.4%
Planned
Maintenance 14.0%
22.5% (28)
Speed losses 57% 4C4I4ACR 4C4I4ACR
8.7%
4CCR 4CCR
Other stops 5C1I1A 5C1I1A
(23,25,26,27) Roto WCM tim
18.7% 4C 4C
Set-up time Flexo Process 5C1I1ACR 5C1I1ACR
(12) Flexo 26.8%
5C1I 5C1I
5C5I5ACR 5C5I5ACR
5C1ICR 5C1ICR
19.8%
55.1%
9.6%
36%
20.5% 20.3%
WCM tim
18
LOSSES are the Key
The Base of the Continuous Improving in WCM
Losses
Standards
Standards
Good
Production
Situation Improve
Eradicate Maintain
/ 19
The WCM Infinity Loop
1 Seek the
losses
2 Eradicate losses
3
Maintain the condition
The Infinite Loop
The Base of the Continuous Improving
5
1 Restore
2 Implement
New
Assess Basic Standards
Current Conditions
Situation
Eliminate
Root
Causes
4
Maintain
the Analyze
Improve
Standards Root
Standards
Reliability Causes
7 3
6
Maintain Eradicate
/ 21
The three TPM Award levels
Linked with business as a whole in a logical expansion
Technology Development
Innovation Chain
Plan
Customers
Suppliers Source Make Deliver and
Consumers
Product Development
Supply Chain
FOCUS LEVEL
TPM
/ 22
Our 11 Pillars of WCM
Each Pillar
Focuses on Common Themes/ Losses
with Expertise in specific Methods and Tools
/ 23
Pillar Activities
Deployment
These are the typical Potential gains
activities carried out Planning teams
Beograd - Srbija
TPM-osnovi
by all Pillars
Evaluation resources
Training
Support
Audits
Monitoring results
Pillars Support on Three Levels
/ 25
AM Man - Machine development
Autonomous
3 Autonomous Kaizen 7 management
Can manage equipment 6 Standardisation
2 Competence and
effectiveness
Knows the function and structure of
5 Autonomous Inspection
equipment and equipment-product
quality relationship 4 General Inspection
1 Change of attitude
Can detect problems and
3 Cleaning and lubrication standards
Together
Employees
Accomplish
More Results
Methodology
People
/ 28
World Class Manufacturing .
1. Data collection
2. Deployment / where are the losses ... /
3. Methodologies and tools / 5S, 4M, 5 Why, ECRS, ...... /
4. Teams
Committees organisation
Teamwork
Approach depth
Managing by Deployment
30
What WCM is about
Involving all the available resources
31
Involve people in a organized way
Team Work
Together
Employees
Accomplish
More
32
Why Team work?
33
How do we organize in Factories?
The three levels in sport and WCM
Football In the Factory
The owners The steering committee
34
WCM must be a real change process
Capable to maintain itself
If any of the steps are missing, we will not have sustainable change
35
World Class Manufacturing
Just common sense?
World Class
Manufacturing opens
minds and doors to new
possibilities
36
WCM is a one-way journey
It works!