CTPM says Coopers Brewery’s maintenance planner Gilbert Bruton shared the company’s learning and experiences on implementing TPM3 at its 2009 Annual Forum.
Coopers Brewery started applying the TPM3 Framework for Lean & TPM in September 2003. The six years of TPM3 improvement activity at Coopers, included 19 twelve week cycles made up of 52 improvement teams involving over 60 people in all parts of the business.
The company applied all ten TPM3 improvement production streams to its Packaged Beer, Kegs & Home Brew/Malt Extracts, and also included TPM3 improvement activities in production support areas such as Maintenance, Quality, Plant Services and Logistics.
As a result of the TPM3 program, Coopers Brewery says it improved the Overall Equipment Effectiveness at its Ale/Stouts division from 68% to 77%, increased its carton per hour rate from 1873 to 2127, and identified six water-saving projects totally 68m litres of water per year.
According to Bruton, intangible achievements include getting an improved understanding of plant and equipment by operators through Operator Equipment Management, and improved problem solving skills and communication.
As part of the process, Coopers Brewery learned about the importance of involving everyone in continuous improvement, the importance of problem solving skills at all levels of the company, the importance of understanding complex processes, and the need to collect and analyse OEE loss data.
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