There were about 20 participants from great companies around Melbourne, including à BlueScope Steel, Asahi, Britax, Devondale, Calalent, Kinross, Marand, Sugar Australia, Anca, Note Printing Australia, Laminex and myself from CSR.
Most of the participants were keen to learn about Denso’s TPM, Operator & Maintenance Team Engagement, Denso’s Maintenance KPI approach and their “Visual Factory” methods in support of Lean Maintenance Systems.
I could write 50 pages on what I learnt in that 3 hours! The highlights for me were:
Focus on MTBF /Recurring Failures (Weekly Reviews & RCA)
Their Operator Asset Care TPM Formats, backup up with “TPM Patrols”
Their monthly “Super PMs” discipline (Aim: Zero Breakdowns!)
Production/Maintenance Collaboration /Teamwork
“TED” Breakdown Response (Communication) Project Boards (BK’s > 2 hours)
Reliability Countermeasures Report (> 3 hours D/T or > 6 Failures/mth)
Maintenance Kaizans
Maintenance “Work In Progress” Room/table and Green Tags
That didn’t include all the Production line “TPS” Lean Operational Excellence best practice (Kanban, Value Stream Mapping & Line Balancing, Standard Work, Team Leaders KPI /Mtg Room, Die Machine Best Practice Targets, Training Skills Matrix Boards, Shift Area Visual Factory Communication Boards, “5S”, to touch on just a few)! I also loved the mobile, adjustable whiteboards. Great idea!
I felt I had a week’s worth of learning at “Denso University”!
Thanks to our hosts, Shyam Dayanand (Divisional Manager, Manufacturing) and David Adams (Maintenance Manager) for a well organised event (including awesome catering!!) And to Jason, Alex, Emil who lead the site inspection teams.
Rick Terpstra, National Program Manager – CSR WAY