Rustem Yildiz is maintenance manager responsible for the Gebze plant which supplies Daimler-Chrysler, Ford, Toyota and Honda on a Just-in-Time basis. From his office, he can access data on the current condition of all the equipment monitored by the Artesis MCM units, and is automatically notified of any changes in status, indicating a potential deterioration in performance. In addition to the excellent downtime figures, he measures the success of the system by a significant improvement in his homelife, resulting from a dramatic reduction in the number of out of hours calls he receives, that previously had disrupted his evenings.
In his opinion, key elements behind the success have been:
· Integration with the Computerised Maintenance Management System. Operations staff are alerted if MCM detects an incipient problem, and this information is directly shown on the Maintenance Management system, so that maintenance staff will be allocated to the job with a works order of the appropriate priority. The system, TACOSOFT, is now being made available more widely for organisations seeking an integrated
The Artesis MCM system is implemented on all the key items of production equipment, including things such as hydraulic presses and water jet cutting equipment. Since implementing the MCM units, they have not had any undetected failures on any of the monitored equipment. The MCM units have contributed to OEE reduction through avoidance of failures, and reduced the Mean Time to Repair (MTTR) – by providing clear guidance on the fault to be corrected.
In addition to the ease of installation, ease of use and robustness of the Artesis MCM solution, one of the big benefits according to Rustem is the ability of the system to identify electrical as well as mechanical problems. He cites the example of an occasion where an early breakdown of insulation in a motor was detected and rectified before the equipment had failed, eliminating a disruptive interruption of production.
As a result of this experience, the Gebze plant has been identified as representing the internal best practice within the Pelzer group, from which it is expected to extend the use of MCM widely across the other plants.
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General Background
Pelzer is a supplier to the automotive industry worldwide, supplying sound insulating linings, carpets and trims on a Just-in-Time basis from 25 plants in countries in Europe, North America, South America and Asia. In this high pressure industry, where the customers include all of the leading car manufacturers, high quality product, with defect rates measured in parts per million is essential, together with high reliability of supply to support the JIT operations. Both of these factors demand the highest reliability of manufacturing equipment.
In this environment, Pelzer has invested in a number of initiatives to improve plant performance and the management of maintenance. The Gebze plant has recently been highlighted as one of the star performers in the Pelzer group, with plant downtime reduced from an already outstanding 0.8% in 2004/5 to 0.6% in 2005/6. One of the key elements in achieving this performance has been the adoption of Artesis’ MCM system on all the key manufacturing equipment items, integrated with the on-line CMMS for fault logging and work management.
