Case Study - Total Productive MaintenanceMajor Steel Manufacturer - NSW, Australia
The Challenge
Excessive unscheduled equipment downtime in our client’s Plate Mill was causing a severe slip in the production schedule.
This in turn, was causing delivery performance problems that were affecting the bottom line.
The Solution
As there were initiatives already underway aimed at minimising unscheduled equipment downtime, EnterpriseIS team members facilitated problem-solving workshops that validated the existing work and also revealed additional initiatives.
These were combined into a programme of work that was scoped and commenced.
The root causes of the top 10 issues of unscheduled equipment related delays were identified, and actions to address them were planned. The focus was on defect elimination.
The areas in which the top 10 issues occurred included:
- The Rotary Trim Shears
- Scrap conveyors
- Top End
- Furnaces
- Labelling Machine
- 3 Marking Machines
- The Table Rolls.
Some of the root causes identified were:
- Daily checks not being carried out
- Alarms not working.
The Results
- The Improvement Project achieved a reduction of over 50% in unscheduled equipment stoppages across all Plate Mill Rolling and Processing areas within 6 months of commencement.