1. Aug 2003MSNBSlide No. 1 Main Business Activities Development Support Operations Development: New products, processes technology Operations: Manufacture, sales of existing products,… All other functions are there to support these two processes

2. Aug 2003MSNBSlide No. 2 External Influences Development Support Operations Markets Suppliers Customers Competitors Interest Rates Laws and Standards Exchange Rates Economy Businesses don’t have much control over these, Must react/respond when any changes occur

3. Aug 2003MSNBSlide No. 3 Internal Factors But businesses can control internal factors which determine how effectively it operates and its ability to respond to external changes.  People  Organization  Systems  Facilities  Technology  Culture

4. Aug 2003MSNBSlide No. 4 Building Blocks of World Class Manufacturing Performance a Development Strategic Direction Effective Material Flow  Layout  Control  Planning  Scheduling  Suppliers Effective Facilities  TPM Components Effective use of people  Organization  Morale  Communication  Training and Development

5. Aug 2003MSNBSlide No. 5 Traditional (breakdown) Maintenance WASTEFUL AND INEFFECTIVE No warning of failure Possible safety risk Unscheduled downtime of machinery Production loss or delay Possible secondary damage NEED Standby machinery Standby maintenance team Stock of spare parts

6. Aug 2003MSNBSlide No. 6 The cost of Reactive (Breakdown) Maintenance Premium time Panic costs Sub contract Lost orders Disruption to other machinery Disrupted Schedules Lost revenue Labor costs Lost capacity Lost Production Maintenance labour Spare Parts Subcontract help Repair Costs Standby machinery Safety stocks ‘Safety’ Costs

7. Aug 2003MSNBSlide No. 7 Vicious Circle of Reactive Maintenance 0 Reacting to breakdowns No Preventive Maintenance No record, organized resources or time Can’t predict breakdowns Why ?

8. Aug 2003MSNBSlide No. 8 TPM and Maintenance Systems TPM – among others, For maintaining and improving the effectiveness of facilities and the overall integrity of production operations Machines do breakdown, when they do, need effective system for reporting, investigating, repairing quickly and cost-effectively, recording information about breakdown. Data also needed for preventive and predictive maintenance tasks

9. Aug 2003MSNBSlide No. 9 Support Total Quality TPM and Total Quality Total Quality Products Transform, add value TPM Production facilities Parts Materials TQM