1. Flexible Manufacturing
The seeking of perfection in manufacturing
John Turner
UK Industries Development Manager

2. Improving productivity
What are our top 5 sources of downtime this shift
Which of these will be easiest to attack?
What action can we take right now to improve this factor

3. Continuous Improvement
Reduced downtime,
Increased production efficiency
Sustainable cost savings
Support Best Practice

4. Total Cost of Ownership
Cost to Create
Design
Acquisition
Training
Life Cycle
Build
Cost to End
Machining
Disposal
Replace
Decommission
Total Cost of Ownership
Cost to Change
Training
Downtime
Re-Design
Integration
Performance
Cost to Operate
Maintenance
Energy Usage
Tooling
Training
Upgrade
Spares

5. Total Cost of Ownership – for a new investment
Early Equipment Failure
Planned Maintenance
Autonomous
Maintenance
Costs
Preparation
Return on investment
Commissioning
End of life
Decline
Time

6. Production Line walk’s
Leading food manufacturer wanted energy savings by reducing compressed air usage as a result of applying best practice techniques.
Solution: Line walk report to identify area for improvement.
H&S LOTO issues identified
Filtration issues identified
Standby Valve opportunities identified
Reduce compressor pressure saves £10K
Leaks, & Air Blast reductions save £3K

7. Productivity New technology valve enabled production cycle increase
Global Beverage manufacturer had line productivity issues due to valve control valve failures.
Solution: New valve solution with a “Hot Change Slice”
Reduced Maintenance time saves £1K
8 hours production loss/year = £240K !
New technology valve enabled production cycle increase

8. Training & Education
Historical No-one is aware what the machine or process actually demands so the highest pressure is adopted
Operator tampering The machine has an issue (maybe speed), and the operator tries to fix themselves
The operator has no idea of what the local setting pressure is / should be
Compensation for inherent pressure drops
Example: A machine consuming 22m3/h (370l/min) at a pressure of 6.5bar will use around 17.5m3/h (290l/min) at 5bar.
A reduction of 1.5bar will equate to approx 10% of the cost of running the compressors……applied across the site…back to the example…that’s a £10K/year saving
Across 23 sites would be £230K/year.

9. A3 Reporting

10. A3 Summary

11. Mobile TPM Display

12. Thank you for your time…
Any questions?