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SAINT-GOBAIN GYPROC Benefits of WCM in maintenance. IRIS Sept 2009. WCM at Saint Gobain Gyproc Results Standards Comments. Agenda. WCM at SG Gyproc. WCM program started on 2002 Worldwide deployment over more than 70 sites Focus on PM. Reactive. Preventive. Proactive. Phase 4.
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SAINT-GOBAIN GYPROCBenefits of WCM in maintenance IRIS Sept 2009
WCM at Saint Gobain Gyproc • Results • Standards • Comments Agenda
WCM at SG Gyproc • WCM program started on 2002 • Worldwide deployment over more than 70 sites • Focus on PM
Reactive Preventive Proactive Phase 4 Seven Steps of Professional Maintenance Phase 3 Phase 2 Phase 1
Benefits of WCM for maintenance in Saint Gobain Gyproc • Share the same vision, have the same targets through the global organisation • Set common high level standards and speak the same langage • Results: Less breakdowns for Less (€, hours)
WCM at Saint Gobain Gypr • Results • Standards • Comments Agenda
39 machines AA at step 3 X • Planned maintenance reduce from 8h/week to 8h every 4 weeks • has been able to follow the market demand and limit the importations
Base 100 in 2003 • maintenance cost reduction together with performance improvment
X = 20% of machines at step 3 X Base 100 in 2003 • maintenance cost reduction together with performance improvment
Base 100 in 2005 • even best plants still improve
Base 100 in 2005 • even best plants still improve
WCM at Saint Gobain Gyproc • Results • Standards • Comments Agenda
Benefits • Results • Standards • Comments Agenda
Plant Manager Details Shopfloor CommitmentMorning Meeting
MaintenanceStep 0 – Engineering Stores • Risk Ranking Score Before: 126 • Time to find Component 60 mins • Failure of component due to poor storage conditions 3 weeks • Risk Ranking Score After: 6 • Time to find Component 60secs • Failure of component due to poor storage conditions – never! Before After
MaintenanceStep 0 – Belt storage After Before
MaintenanceStep 0 – Belt storage After Before local clos ventilé avec système anti-poussière, Installation d'un contrôle de température et hygronométrie
MaintenanceStep 0 – Bearings storage Before After
Step 0 – Engineering StoresElectrical components Before After
MaintenanceStep 0 – Engineering workshop Before After
Lubrication Store After
Lubrication Store Before After
Lubrication Store After Before
Lubrication Store Before After
WCM at Saint Gobain Gyproc • Results • Standards • Comments Agenda
What has changed in our maintenance strategy • Prioritisation based on losses and machine classification.before, try to do all machines and never succeed • Nb of subcontractors limited focus on our internal ressources subcontractors better controlled • With operators doing AM, PM activities have gone from BM to TBM and now CBM • Better involvment via teamwork, OPL, QK…
Successes and difficulties • Success : • go back to basics • results • Difficulties : • ability to change to a new system • autonomy • respect standards
Impact of local cultures • Germanic cultures: Long to join in, because having an existing strong system • Eastern cultures:Technological background well adapted but bad experience from window-dressing in ex-communist countries • Latine cultures:Not used to respect standards • Unions:Need to have them on board, depends on local « political » issues.(NA, South Europe)