The client has multiple battery manufacturing factories across the world. They were in a difficult situation with regards to equipment reliability and breakdowns. The OEE was not measured and the shop floor people were not engaged with day to day taking care of their equipment. High level of Breakdowns, short stops, and Quality issues. A large disconnect between the current CI activities and shop floor engagement.
Productivity and Cost targets have not been achieved consistently for the past few years. I operate You fix it mentality. Run it to failure mindset for many years in past in most plants. In most of the plants, the ratio of Proactive Maintenance VS Breakdown Maintenance was 10% PM VS 90% BD. Equipment was not planned properly or managed properly by the operating crew or by maintenance technicians.
High level of employee lack of involvement at shop floor level, and understanding how to drive improvements while delivering required results.
Silo mentality among the functional departments at most of the plants. Maintenance has been seen as “does not add value”.
Lack of Loss intelligence and understanding how to drive OEE to world class levels.
Change management training and workshop with the leadership of each plant. Launched Pilot team activities across multiple sites at different types of equipment’s with a team of supervisors, operators and technicians. Established the TPM Pillar system, defined roles and responsibilities for all levels in the organization. Defined the necessary organizational structure at each site for the successful integration of daily activities with TPM. GEMBA and Kaizen activities on the shop floor in order to transfer the responsibility and ownership to the shop floor personnel.
Achieved outstanding involvement and engagement thru the shop floor activities with the leadership team direct involvement. Operators understood and mastered on taking care of their equipment thru Autonomous Management activities thru Daily Cleaning, Inspection and Lubrication tasks in their work areas and equipment, that resulted in significant OEE improvements and productivity improvements thru the early detection of failures and or symptoms of failures.