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A pioneering production process which originated in Japan in 1971 is being implemented in several component companies in the Eastern Cape.
The Eastern Cape Automotive Cluster today introduced the Total Productive Maintenance approach at five companies on a pilot basis.
The TPM approach in essence draws a machine operator into the entire maintainence process and through training is then able to perform many of the daily tasks of simple maintenance and trouble-shooting and in so doing can prevent costly down time.
Lance Schultz of the Automotive Industry Development Centre, says local introduction of the Total Productive Maintainence programme, was the result of a recent visit to India.
"The TPM approach is centred on a partnership with machine operators in a plant to ensure that machines operate at maximum capacity for the duration of their lifespan. This partnership ensures that stoppage time is greatly reduced and efficiency and cost effectiveness increased,'' Schultz said.
"In contrast to the leading suppliers globally where TPM is meticulously implemented and evaluated on a daily basis, in South Africa the approach is haphazard and unstructured,'' he added.
In announcing the programme Eastern Cape Automotive Cluster programme leader Gareth Fismer said the introduction for the first time in the country of Total Productive Maintenance was "an important day for the automotive industry and the beginning of a journey that would drive down costs and increase the global competitiveness of suppliers.''
Fismer said the TPM programme would run over three years after which suppliers could apply for TPM certification, which "is one of the most highly regarded business excellence certifications with global OEM's currently.''
The TPM programme was launched this week to the participating suppliers, with the expectation that after full implementation machine stoppages would be reduced by up to 80% at participating suppliers and subsequently quadruple plant capacity.
This programme is one of the first major initiatives of the Eastern Cape Automotive Cluster, established in March 2011 by industry and the Eastern Cape Province.
From the left standing Casey Beary (Tenneco Ride Control), AIDC Senior Project Manager, Zahier Ebrahim and seated from left Craig Ehlers, SJM Flex Works Manager, and CRH Africa Plant Manager, Gareth Fismer.
