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
World Class Manufacturing - NSA

©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
Ata Reunião#13 Alexandre
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
Ata Reunião#13 Alexandre
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
Ata Reunião#14 Alexandre
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
World Class Manufacturing - NSA

©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

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.
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

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.
Standard Procedures
Cleaning & Inspection

©2012Novelis Inc.
Mapping
Lubrication

LUBRICATION POINTS

©2012Novelis Inc.
Monitoring
Lubrication Plan

©2012Novelis Inc.
OPC
Step 4

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.
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

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.
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
World Class Manufacturing - NSA

©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
 Basic Knowledge: 34
 Improvement Cases: 18
 Problem Cases: 9

©2012Novelis Inc.
SCALPER Indicators
Step 1
Blue Tags Monitoring 82,7% Red Tags Monitoring 78,7%

• Opened: 75 • Opened: 94
• Closed: 62 • Closed: 74

Number of OPL’s by Categories

• Total Elaborated: 27
 Basic Knowledge: 18
 Improvement Cases: 7
 Problem Cases: 2

©2012Novelis Inc.
SL1 Indicators
Step 1
Blue Tags Monitoring 100% Red Tags Monitoring 60,0%

• Opened: 131
• Closed: 79
• Opened: 209
• Closed: 209

Number of OPL’s by Categories

a r
a l iz
• Total Elaborated: 10
u
 Basic Knowledge: 9
 Improvement Cases: 1
 Problem Cases: 0
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.