7/28/2019 FM Cell 13 TPM

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Improvement

Activity

TPM

Total Productive Maintenance

Peter Rogers

Senior Consultant

Company

Federal Mogul

(Ferodo)

Richard Hollister

Senior Production Manager

Kaizen Case Study

Company Background

Federal Mogul Friction Products based in Chapel-en-le-Frith manufactures Brake Pads

for supply into automotive and transportation market sectors.

The site is undertaking a lean transformation consolidating its operations from the

current two sites into one Building. The vision for the one building project is of a plant

running at high efficiency using Just in Time methodology positioning itself as a world-class first tier supplier.

The main focus of the improvement activity is to understand and to implement TPM

(Total Productive Maintenance) methodology to increase machine performance, output,

on time delivery and inventory reduction.

Kaizen Activities Deployed

An improvement project utilising a cross function team was undertaken on cell 13. Cell 13is one of 6 cells that converts raw mixture into formed brake pads.

Improvement activities undertaken included :-

Operator lean awareness

Development and deployment of daily OEE

5S

TPM resulting in routine asset care to ensure

machine performance

www.uk.kaizen.com

Results

OEE increase from baseline of 60% to 85% after 12 weeks following the activity

Improvement of workplace organisation and reduced health and safety incidents

Increased understanding, accountability and responsibility of the cell by the operating staff

Asset care routines established for by operating and maintaining staff

Improved data collection routines and visual management

26% increase in capacity resulting in 8,500 extra brake pads per week Further defined and agreed plan to increase the OEE to 95% thorough further Kaizen activity

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7/28/2019 FM Cell 13 TPM

2/2

Improvement

Activity

TPM

Total Productive Maintenance

Peter Rogers

Senior Consultant

Company

Federal Mogul

(Ferodo)

Richard Hollister

Senior Production Manager

Kaizen Case Study

www.uk.kaizen.com

Page 2 of 2

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W46

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W 1 W 2 W 3 W4 W5

Cell 13 Weekly OEE OEE Data Collection

Availability from 67% to 90%

Performance from 86% to 90%

Quality consistently at 99%

OEE(Overall Equipment Effectiveness)

from 60% to 85% in a 12 week period

5S

5S workshop completed

Improved health, safety and ergonomics Increased operator value add

Visual standard on the cell showing hour

by hour line standard

Improved operator ownership

Audit mechanism in place

1st level machine refurbishment

TPM

Increased understanding of the asset

using criticality assessment methodology

2nd level machine refurbishment following

condition appraisal path

Asset care routines defined by operator

and tradesman resource

Critical spare parts established

Reduction of fire-fighting activity Consistent machine output