5 days to success

An example of field training and deployment of TPM

The client company manufactures electronic systems for automotive industry. The major car makers are her customers. these customer are extremely demanding and perform regularly audits at their suppliers premises.

This company had already a good knowledge and maturity about tools and methods. Automatic insertion machines setup in lines provide electronic boards to next final assembly stations. These equipment are highly automated, yet they lack production capacity as they are often down. Main reason were failures and breakdowns. Other phenomenon burden production time as well and extend the changeover durations.

Training objectives

The client company wants to deploy in a very operational manner the TPM approach in order to:

• Raise the equipment reliability
• Improve production capacity without additional investments or at least to postpone new investments
• Use available resources more efficiently
• Reinforce motivation on subjects already addressed but poorly worked out

Training

The suggested training content was a mix of theory (the necessary basics) and immediate application on a pilot line.

The training itself was flexible and opportunistic, so to use any event in the line's day (changeovers, normal speed, specific event, stops, breakdowns...). Nevertheless, the whole content was delivered to the trainees.

Five full days gathered groups of 10 to 12 trainees, among which operators - the closest to the machines -, technicians, line leaders, workshop manager and members of continuous improvement team.

Results

After two training sessions, following results have been recorded:

• 60 improvement suggestions during training. Rediscovering the (familiar) facilities and group emulation highly stimulated the trainees

• 20 action plans for the short term and managed by the trainees themselves have been launched during the training. Deadlines were 3 months maximum

• +3 points of progress on performance indicator (inspired of OEE) just after training and a steady progress of 1 point per month, for each of the two pilot lines
   

Evaluation

On the last day of each training session, with attendance of top management, a debrief was performed by the trainees themselves. They summarized the achievements and links with training content and explained the actions they´ll work on.

• Trainees found motivation and self esteem additionally to training content

• Top management saw the results and positive outputs of the training and got a hint about the payback!

• The consultant and his organization have been valued through the good results

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