Plant management system implementation

The process optimisation focus of the enterprise implies the research of other productive models different from the traditional one of the graphic arts. It was necessary to go over the management schemes of the sector, and to adopt a new model: “Following the TPM principles, we understood that what we should observe closer in our production plants were the machines”.

Needs

• The work report was completed directly by an operator in a PC in the plant. This productivity control system gave good results for a period, but quickly arrived to its limit.
• The tools and indicators of plant management were focused on measuring the operator’s productivity, not allowing to identify real improvement opportunities.

Objectives

• Implement a new management methodology based on TPM, supported by an information system
• Orientate the increase of productivity based on the locations loss value analysis
• New environment management definition, fed with TRUTHFUL information
• Implementation
• After the implementation in a pilot zone, the project evolution was evaluated
• Later, the necessary methodological assembly was prepared in order to convince directors and operators of the new model, and go over mental barriers
• The system has currently spread out to all productive lines

Results

Evolution from evaluating the productivity with graphic arts criteria to manage with OEE

Deeper knowledge of reality, having at its disposal information about many incidences, before unnoticed

Evolution from a philosophy oriented to press the operator to having information to analyse differently every single line: “The problem was not so focused in the performance, but in the availability, an aspect not considered until this period”