WCM OPC Pillar: Grand Prix of Excellence - NSA

Pinda, Aug/16
WCM
OPC Pillar
Grand Prix of Excellence - NSA
Tadeu Granato
Reliability Coordinator
©2012Novelis Inc.
Introduction
World Class Manufacturing - NSA
©2012Novelis Inc.
What is it
about?
 An employee engagement program to improve ownership

and the awareness about asset care;
 Enhace discipline in executing basic activities by operators

and the rest of the team;
 Improve craftsman understanding about how the equipment

works and make him able to spot signs of trouble;
 In final steps, operators will execute basic maintenance that

can be easily performed on a daily basis, e.g., inspection,
cleaning, lubrication, etc...
©2012Novelis Inc.
What is it
not?
 Replace maintenance crew by operator;
 An activity to keep operations busy when product demand is

low;
 Doing a favor for Maintenance team;
 Performing basic maintenance without a purpose;
 Making operators into skilled tradesman.
©2012Novelis Inc.
Seven Steps of
Operator Care
7
Autonomous Maintenance
6
Standardization
5
Autonomous Inspection
4
General Inspection
3 Create and maintain standards of cleaning, inspection
and lubrication
2 Eliminate sources of contamination and inaccessible areas for
inspection and cleaning
1
Organization and planning - Initial Cleaning
©2012Novelis Inc.
Implementation
Steps vs Activities
©2012Novelis Inc.
OPC
Action Board
©2012Novelis Inc.
How OPC
works
We are here!
©2012Novelis Inc.
OPC
Paradigm Shift
Operator
Old Care
Attitude Attitude
Illustrative
©2012Novelis Inc.
OPC
Main Goals
©2012Novelis Inc.
Operator Care Pillar
©2012Novelis Inc.
Pillar
Members
©2012Novelis Inc.
OPC
Cockpit
©2012Novelis Inc.
Responsabilities
Matrix
©2012Novelis Inc.
Meeting
Contract
Quadro de Referência Pilar Operator Care

Reunião: Pilar Operator Care Participantes: Objetivos:
Frequência: Quinzenal - Líder do Pilar - Assegurar os resultados
Data: Terça-feira - Membros do Pilar - Analisar o cronograma de implementação
Horário: 13:30 - 15:00 - Membros de implantação nas áreas* - Definir as prioridades
Local: Sala WCM - Coordenador WCM* - Assegurar a comunicação do projeto
- Consultor da Boaz & Goldstone Consultants* - Apoiar e fomentar o projeto e remover os obstáculos
* Eventualmente

Documentos a analisar Documentos produzidos:
- Plano de ação - Ata de reunião
- Master Plan Implementação (Pilar e GA's) - Cockpit atualizado
- Resultados da auditoria - Plano de ação

Agenda: KPIs para rever: Regras básicas:
1. Plano de ação - Downtime RECII (Área Fria) - A reunião começar no horário
2. Revisão do estado dos KPIs - Downtime Tandem - Todos os participantes estar no horário
3. Resultados das auditorias - Downtime Faceadeira - Reunião centralizada
4. Implementação - Downtime RM1 - Todos os membros participarem ativamente
- Implementação numero áreas - Planejado
x Realizado - Respeitar o tempo da reunião
- Estabelecer prazos claros e responsáveis para as ações
- Discussão construtiva

©2012Novelis Inc.
Action
Plan
ACOMPA
DESCRIÇÃO NHAMEN
TO
DATA
STATUS ORIGEM AÇÃO QUEM QUANDO COMENTÁRIOS
ENC
Ata Reunião#13 Alexandre
Encerrado Validar o Master Plan de implantação do Pilar 05/16/16 06/15/16
10/05/16 Fernandes
Encerrado Atualizar o plano de atividades no Cockpit do Pilar 05/24/16 06/15/16
10/05/16 Fernandes
Pend - Ata Reunião#13
Revisar a matriz de responsabilidades do grupo do Pilar Tadeu Granato 08/02/16 Com apoio dos membros do Pilar
Atrasado 10/05/16
Encerrado Atualizar o Contrato de Reunião do Pilar 05/24/16 06/06/16 Com apoio dos membros do Pilar
10/05/16 Fernandes
Ata Reunião#14
Encerrado Revisar a folha de auditoria do Passo 3 Tadeu Granato 05/31/16 05/31/16 Realizado pelos membros do Pilar
31/05/16
Ata Reunião#14
Encerrado Validar com a consultoria sobre a revisão da folha de auditoria OPC Passo 3 Tadeu Granato 06/21/16 06/20/16
31/05/16
Encerrado Definir cronograma de auditorias internas para os Times OPC 05/31/16 05/31/16 Definido que será quinzenalmente à partir do dia 06/06 para todas as áreas
31/05/16 Fernandes
Ata Reunião#15
Encerrado Rever o treinamento do Passo 2 Marcos Santos 07/31/16 08/02/16
07/06/16
Pend - Ata Reunião#15 Exemplo da RM1 - Não estão abrindo etiquetas devido dificuldade para emitir a
Incluir o processo de abertura da Solicitação de Serviço no treinamento do Passo 1 Tadeu Granato 08/30/16
D_Prazo 07/06/16 Solicitação de Serviço.
Pend - Ata Reunião#16 Preparar o treinamento de abertura da Solicitação de Serviço para ser incluído no
Paulo Castilho 08/30/16
D_Prazo 21/06/16 treinamento do Passo 1
Pend - Ata Reunião#16 Alexandre
Elaborar o template do Portal dos Grupos Autônomos 07/19/16
Atrasado 21/06/16 Fernandes
Ata Reunião#17
Encerrado Definir padrão do indicador de Downtime através da GRO Tadeu Granato 08/02/16 08/02/16
12/07/16
Ata Reunião#17 Verificar com a Consultoria sobre a real necessidade de se criar o quadro de gestão de Alexandre
Encerrado 07/26/16 07/26/16
12/07/16 inspeções da área Fernandes
©2012Novelis Inc.
Audit
Report
©2012Novelis Inc.
Operator Care Implementation
©2012Novelis Inc.
Timeline
2016 - 2017
STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7
WORLD CLASS MANUFACTURING IMPLEMENTATION

Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar
2016 Actual
Date
2017
OPC REC II 3 4 5
OPC TDM 5 6
OPC SCA 1 2 3 4
OPC SL1 1 2 3 4
OPC LINE A 1
OPC CM2 1
©2012Novelis Inc.
OPC
Step 1
7 Autonomous Maintenance
6 Standardization
5 Autonomous Inspection
4 General Inspection
3 Create and maintain standards of cleaning, inspection and

lubrication
2 Eliminate sources of contamination and inaccessible areas for inspection and
cleaning
1
Organization and planning - Initial Cleaning
©2012Novelis Inc.
Initial
Cleaning
©2012Novelis Inc.
Tagging
System
Blue Tags Monitoring 97,3%
• Opened: 2589
• Closed: 2520
Red Tags Monitoring 90,2%

• Opened: 2637
• Closed: 2379
©2012Novelis Inc.
OPL’s
Examples
BASIC KNOWLEDGE IMPROVEMENT CASES PROBLEM CASES
©2012Novelis Inc.
OPL’s
Monitoring
©2012Novelis Inc.
Mapping - Technical Cleaning
and Inspection
TECHNICAL CLEANING POINTS
©2012Novelis Inc.
Planning
Technical Cleaning
©2012Novelis Inc.
OPC
Step 2
6 Standardization

lubrication
2 Eliminate sources of contamination and inaccessible areas
for inspection and cleaning
1 Organization and planning - Initial Cleaning
©2012Novelis Inc.
Mapping - Sources of Contamination and
Inaccessible Areas to Clean
Before
After
05POINTS
08 POINTSOF
OFSOURCES
SOURCESOF
OF 22 POINTS OF
09
CONTAMINATION
CONTAMINATION INACCESSIBLE AREAS TO
CLEAN
©2012Novelis Inc.
OPC
Step 3
6 Standardization
3 Create and maintain standards of cleaning,

inspection and lubrication
cleaning
©2012Novelis Inc.
Standard Procedures
Cleaning & Inspection
©2012Novelis Inc.
Mapping
Lubrication
LUBRICATION POINTS
©2012Novelis Inc.
Monitoring
Lubrication Plan
©2012Novelis Inc.
OPC
Step 4
6 Standardization
4
General Inspection
lubrication
cleaning
©2012Novelis Inc.
Study
Functional Group
SPRAY BAR
OIL MIST
©2012Novelis Inc.
Oil Mist Training
Autonomous Group
Components Operating Principle Operating Principle
Lubrication Points Adjustments Standards
©2012Novelis Inc.
Autonomous Group
Failure Analysis Method
©2012Novelis Inc.
OPC
Step 5
6 Standardization
5
Autonomous Inspection

lubrication
cleaning
©2012Novelis Inc.
Inspection
Check Lists
©2012Novelis Inc.
Quality Points
List
©2012Novelis Inc.
Unified
Check List
©2012Novelis Inc.
Unified Inspection
Points
©2012Novelis Inc.
Inspection Points
Identification Plates
©2012Novelis Inc.
Key Indicators
©2012Novelis Inc.
Internal Audit
Results
TDM – STEP 5 RECII – STEP 4
Points
Starting
Step 4
Weeks
SCALPER – STEP 1 SL1 – STEP 1
©2012Novelis Inc.
TDM Indicators
Step 5
Blue Tags Monitoring 97,3% Red Tags Monitoring 90,2%
• Opened: 2637
• Opened: 2589 • Closed: 2379
• Closed: 2520
Number of OPL’s by Categories Operator Care Voices - Downtime Indicators
 Basic Knowledge: 86
• Total Elaborated: 179  Improvement Cases: 41
 Problem Cases: 52
©2012Novelis Inc.
REC II Indicators
Step 4
Blue Tags Monitoring 100% Red Tags Monitoring 86,4%
• Opened: 2464
• Closed: 2464 • Opened: 405
• Closed: 350
Number of OPL’s by Categories
• Total Elaborated: 61
 Improvement Cases: 18
©2012Novelis Inc.
SCALPER Indicators
Step 1
Blue Tags Monitoring 82,7% Red Tags Monitoring 78,7%
• Opened: 75 • Opened: 94
• Closed: 62 • Closed: 74
©2012Novelis Inc.
SL1 Indicators
Step 1
Blue Tags Monitoring 100% Red Tags Monitoring 60,0%
• Opened: 131
• Closed: 79
• Opened: 209
• Closed: 209

a r
a l iz
u
At
©2012Novelis Inc.
OPC
How to Sustain?
 Active project sponsor and leadership
 Program should be owned by operational teams and supported

by all other different teams (engineers, process, HR,
communication)
 Time required for cleaning and lubrication must be included in

daily schedule
 Supervisors need to ensure Operator Care activities are

performed
 Utilize oficial maintenance work flow when requesting any

maintenance work
©2012Novelis Inc.
Chalenges to
Overcome
 Amount of resources for

cleaning protocols;
 Initial red tags: additional

maintenance work;
 Staff were not properly

brought into the process;
 Mills are dirty Environment;
 Competing activities.
©2012Novelis Inc.
©2012Novelis Inc.

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Pinda, Aug/16

 An employee engagement program to improve ownership

 Enhace discipline in executing basic activities by operators

 Improve craftsman understanding about how the equipment

 In final steps, operators will execute basic maintenance that

 Replace maintenance crew by operator;

 An activity to keep operations busy when product demand is

 Doing a favor for Maintenance team;

 Performing basic maintenance without a purpose;

 Making operators into skilled tradesman.

Quadro de Referência Pilar Operator Care

WORLD CLASS MANUFACTURING IMPLEMENTATION

3 Create and maintain standards of cleaning, inspection and

Red Tags Monitoring 90,2%

TECHNICAL CLEANING POINTS

3 Create and maintain standards of cleaning, inspection and

3 Create and maintain standards of cleaning,

1 Organization and planning - Initial Cleaning

1 Organization and planning - Initial Cleaning

Components Operating Principle Operating Principle

Lubrication Points Adjustments Standards

3 Create and maintain standards of cleaning, inspection and

1 Organization and planning - Initial Cleaning

Number of OPL’s by Categories Operator Care Voices - Downtime Indicators

Number of OPL’s by Categories

Number of OPL’s by Categories

Number of OPL’s by Categories

 Program should be owned by operational teams and supported

 Time required for cleaning and lubrication must be included in

 Supervisors need to ensure Operator Care activities are

 Utilize oficial maintenance work flow when requesting any

 Amount of resources for

 Initial red tags: additional

 Staff were not properly

 Mills are dirty Environment;

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