owens corning creating the global roadmap · 1980. 8. 15. · new fiberglass wool, effectively...
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Copyright © 2016 Owens Corning. All Rights Reserved.
OWENS CORNING COMPOSITE SOLUTIONS
COMPANY & BUSINESS OVERVIEW
Andy Maclean Director – Global Quality & TPM
Composite Solutions Business
WHY CHOOSE OWENS CORNING? OWENS CORNING AT A GLANCE
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Founded in 1938 2015 sales: $5.4 billion 15,000 employees in 26 countries FORTUNE®500 company for 62 consecutive years Component of the Dow Jones Sustainability Index
Composites Roofing Insulation
THREE MARKET-LEADING BUSINESSES
COMPANY HIGHLIGHTS
1. Owens-Corning Fiberglas Corporation was founded on Oct. 31, 1938
2. Owens Corning and General Motors announced the first production automobile to be made entirely of Fiberglas™ -reinforced plastic, the Chevrolet Corvette, in 1953
3. In 1956, red dye was added to the binder in a new fiberglass wool, effectively introducing what would become Owens Corning’s renowned PINK® Fiberglas™ insulation
4. In the post-war years, Owens Corning expanded its product range to support the first Fiberglas™-reinforced plastic fishing rods, serving trays and pleasure boats
5. After a tragic fire claimed the lives of several astronauts, Beta® Fiberglas™ yarn became the standard for all Apollo program space suits
6. In 1975, Owens Corning was awarded the contract to make and install insulation for the 800-mile Trans-Alaska Pipeline
7. The Hajj airport terminal in Saudi Arabia is constructed with a 105-acre Fiberglas™ roof
8. The Pink Panther debuted as the corporate mascot for Owens Corning on Aug. 15, 1980
9. Owens Corning moved into its current world headquarters campus in 1996
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1 2 CLOCKWISE FROM TOP LEFT:
A STRONG BUILDING MATERIALS BRAND
#1 Brand in Homeowner Awareness
Insulation: 72%
Roofing: 56%
Intellectual property with PINK brand and THE PINK PANTHER™
48% of homeowners associate Pink Panther™ with Owens Corning
Returned to national advertising August 2013
Source: Owens Corning Proprietary research, March 2013 and August 2014 4
BRAND PREFERENCE DRIVES PULL THROUGH
OUR ROOFING BUSINESS
Attractive industry with growth opportunities
High-performing product lines that benefit from vertical integration
Roofing components that enhance overall roof performance and deliver strong margins
Track record of strong financial performance
STRONG BUSINESS POSITIONED FOR GROWTH AS MARKET RETURNS TO HISTORICAL DEMAND LEVELS
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FIBERGLAS™ INSULATION
A product and market created by Owens Corning
Safe, proven, versatile and sustainable
For residential, commercial and industrial applications
EcoTouch® Fiberglas™ insulation – made with at least 50% recycled content, including at least 30% post-consumer recycled content
Manufactured in a dozen plants in the U.S. and Canada to provide customers with responsive service
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Applications
Processes
1932-1946 Start of the industry
OC introduces fiberglas
Commercial Boat Hulls
FRP Car Body (Stout Scarab)
CSM / CFM Process
Resin Systems Developed
Hand Lay-up Process
1947-1960 Niche Applications
Chopped Strands Process
Carbon Fibers Developed
Direct Roving Process
Spray-up Process
Pultrusion Process
Commercial FRP Car Body
Composite Panels (trucks)
Helicopter Blades (Alouette II)
1961-1978 Industrial Applications
Filament Winding Process
SMC Process
High-Strength Glass Process (S)
Kevlar® Fibers Developed
Glass Reinforced Thermoplastics
SMC Air Deflector
Glass Mat Reinforced Shingles
Commercial Wind Turbine Blades
1979-1996 Corrosion Resistance
Continuous Fiber Thermoplastic Laminates
Long-fiber Thermoplastics
Composite Storage Tanks
Fiberglass Windows
Hybrid Front-End Modules
1997-Present Hybrid Technology Integration
Hybrid Molding technologies
Commercial Wind Turbine
Commercial Aircraft
Structural Automotive Parts
Consumer electronics
APPLICATIONS AND PROCESSES
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0
1MM
2MM
3MM
4MM
5MM
Graph depicts glass fiber market demand, in kilotons Kevlar is a registered trademark of E. I. du Pont de Nemours and Company
OWENS CORNING’S COMPOSITE SOLUTIONS BUSINESS
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AMERICAS
Brazil Rio Claro (2)
Canada Guelph
Mexico Mexico City Tlaxcala
United States Aiken, SC Amarillo, TX Brunswick, ME Ft. Smith, AR Gastonia, NC Jackson, TN Starr, SC Wichita Falls, TX
EUROPE
Belgium Zele
France Chambery L’Ardoise
Italy Besana
Netherlands Apeldoorn
ASIA PACIFIC
China Changzhou Doudian Yuhang
India Taloja Thimmapur
Korea Kimchon
Russia Gous
Spain San Vicente
United Kingdom Liversedge
6,800 employees worldwide;
27 plants in 14 countries; 5 R&D centers
Fabrics Operations Non-Wovens Operations Other Glass Reinforcements Operations
WHY CHOOSE OWENS CORNING? OUR GLASS REINFORCEMENT PRODUCTS AND THEIR APPLICATIONS
CHOPPED STRAND MAT AND CONTINUOUS FILAMENT MAT
Marine, transportation, recreation, corrosion resistance, construction
Construction, industrial, automotive, road paving
NON WOVEN VEIL
Wind, pipe, thermoplastic composites, industrial, recreational
KNITTED OR WOVEN FABRICS
Construction (panels and translucent panels), corrosion resistant pipe and tanks, consumer (sanitary, recreational vehicles), transportation (headliner, body parts, semi-structural parts)
CONTINUOUS FIBER MULTI-END ROVING
Transportation, consumer electrical/ electronics and appliances
CHOPPED STRAND, DRY-USE
Building products (roofing and gypsum), industrial specialties
CHOPPED STRAND, WET-USE
Chemical and sewage, oil, water processing (pipe and tanks), industrial (high-pressure vessels, pultruded items), wind energy, aerospace, ballistics, transportation (muffler filling), electrical (optical cable)
CONTINUOUS FIBER TYPE 30® SINGLE END ROVING
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ADDRESSING ALL MARKET SEGMENTS AND NEEDS
© shutterstock.com; © iStock picture
INDUSTRIAL
TRANSPORTATION
WIND ENERGY
BUILDING & CONSTRUCTION
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OWENS CORNING SAFETY JOURNEY
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Copyright © 2016 Owens Corning. All Rights Reserved.
OWENS CORNING TPM
CREATING THE GLOBAL ROADMAP
Andy Maclean Director – Global TPM & Quality
Composite Solutions Business
TPM IS NOT: TOTALLY PAINTED MACHINES
MAINTENANCE “Maintaining or being maintained; keeping going; keeping in repair; supporting, without impairment”
PRODUCTIVE “The achievement of Zero Injuries, Zero defects and Zero Losses”
TOTAL “The Involvement of everyone in structured teams (Pillars) working to a common goal”
WHAT IS TPM?
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TPM APPROACH
By Establishing & Maintaining Optimal Conditions at all times, the process outputs become predictable and controllable. But this requires inputs and processes to be designed, implemented, operated and maintained in an optimal way:-
Process
Safety : Zero Injuries Quality : Zero Defects Cost : Zero Losses Delivery : Zero Losses
People : Materials : Equipment : Methods : Environment :
Optimal Outputs Optimal Inputs
The process should operate as intended, when intended, for as long as intended without unplanned interruption ...
KEY CONCEPTS OF TPM
System TPM is a system, not a set of tools
Overlapping teams of people working to a common goal
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Skills TPM is a skill improvement program
Pillars
Deterioration All things deteriorate either naturally or forced
Loss Chronic & Sporadic needs to be fully understood
Zero The goal is Zero Injuries, Zero Defects, Zero Losses
2012 : Start TPM EU & AP GRS
2016 Start TPM in ISB (Waxahachie)
<2010 : CI Lean
2010 Initial TPM Pilots in GRS NA
2012 : Start TPM in Tlaxcala
2014 : Start TPM in NW
2015 : JIPM Excellence Award Tlaxcala
2016 Start TPM in Fabrics
2016 Start TPM in R&A (Irving)
JIPM Assessment - Yuhang
JIPM Assessment - Taloja
Pilot Phase
Expansion Phase
Pilot Phase
“TPM will be the way we operate, maintain and improve
our operations”
THE OC TPM JOURNEY (SO FAR)
EXAMPLE: CHINA – AUTONOMOUS MAINTENANCE
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1. INITIAL CLEANING
2. ELIMINATE SOURCES OFCONTAMINATION, ETC.
3. CREATE & MAINTAIN INITIAL STANDARDS
4. GENERAL INSPECTION
5. AUTONOMOUS INSPECTION
6. STANDARDIZATION
7. AUTONOMOUS MANAGEMENT
All Processes Deteriorate Forced deterioration accelerates the onset of process of failure
CONTAMINATION DAMAGE VIBRATION
GOAL: Eliminate forced deterioration of process and equipment by engaging all
personnel in maintaining optimal conditions
Key Characteristics of Good Autonomous Maintenance
1) Tags – Increasing and being solved 2) Autonomous Teams (including maintenance) 3) AM Team Board (used by the team) 4) One-Point Lessons (regularly generated and
used) 5) Cleaning Time – Increases, then reduces
EXAMPLE: CHINA
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ZHU DENGFENG Batch House AM Trainer
“AM activity changed our mindset from, ‘I operate, you fix,’ to ‘I take care my machine.’”
“AM also improved our ability and critical eye, not only operate the machine correctly, but also to know how to maintain the machine and repair it; that is why 85% of leaks (have been) eliminated by us.”
Y2012 Y2013 Y2014 Y2015 Y2016 YTD Y2016Target
Product Unit Cost
0.28 0.30 0.30
0 0 0 0 0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
Safety-Recordable Injure Rate Rate
TPM TANGIBLE ACHIEVEMENT EXAMPLE - CHINA
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NE% (Net Efficiency) %
Y2012 Y2013 Y2014 Y2015 Y2016YTD Y2016 Target
Nu
mb
er
Customer Complaint Number
The consistent TPM activity brought lots of qualitative benefits that cannot be
measured but can be felt throughout the plant.
Initiative Every employee in the organization realizes all the abnormities as
losses, report them through tagging process and always think how to improve as first response.
Mindset The change from the “quick fix” culture to “find & eradicate root cause”
culture.
Growth Build best practice sharing phenomenon within plant through One-Point- Lesson program; everybody can be instructor to grow himself.
Empower The feeling of self-empowerment in all levels of the organization.
Recognition The recognition of “people as our most valuable assets.”
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TPM INTANGIBLE ACHIEVEMENT EXAMPLE - YUHANG
IMPROVEMENT EXAMPLES
Before Current
INDIA
INDIA INDIA
INDIA
BRAZIL BRAZIL
IMPROVEMENT EXAMPLES
Before Current
TPM ROADMAP
Plant TPM Launch Model
M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12 M13 M14 M15 M16 M17 M18 M19 M20 M21 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4
Prerequisites
Year 2 Year 3Year 1
Preparation Phase (3 months) Model Area Phase (6 months) Expansion Phase Year 1 Expansion Phase Year 2 Exp. Phase Year 3
Union
Engagement
Objectives
1 year3 year
X Matrix
Org. Review
for TPM
Regional Leader
TPM Awareness
Formal
Announcementto Plant Team
5S Training
and launch
Daily
ManagementObeya/Huddle
TPM Leader
Assigned
TPM Foundation
Training, all employees
Establish
SteeringCommittee
Plant Leader
TPM Awareness
Plant Leader
Role/Resp
NLT Pillar
Training
Pillar Leader
Selection
Pilot Area
Masterplan
Site TPM
Boot Camp (1)
Lessons
Learned
Losses Data
System Reviewand Action Plan
NLT 'Adopt a
Machine'
Readiness
Assessment (2)
Pilot Area
Selection
AM Pilot Area
PM Pilot Area
T&D Pilot Area
FI Pilot Area
T&D Pillar Launch
FI Pillar Launch
AM Pillar Launch
PM Pillar Launch
Readiness
Assessment (1)
TPM
Assessment
Pillar Teams
Selection
Plant
Masterplan
NLT Best
Practice Plant Visit
EM Pillar Launch
OE Pillar Launch
QM Pillar Launch
PM Pillar Launch
TPM
Assesssment
TPM
Assesssment
JIPM
Readiness Assesssment
Preparation
Pilot Phase
Expansion Phase
Management Declaration Establish Key Enablers (Daily Management) Organisation & Skills
Management Learning Machine Establish Pillars & Steering Demonstrate Step by step approach Establish results
Expansion of pillars Expansion across facility Ongoing Assessment of TPM
TPM GOVERNANCE
Global
TPM Leader
Global
Pillar
Leaders
AM
PIL
LA
R T
EA
MS
AM
PIL
LA
R T
EA
MS
AM
PIL
LA
R T
EA
MS
AM
PIL
LA
R T
EA
MS
AM
PIL
LA
R T
EA
MS
GL
OB
AL
LE
VE
LR
EG
ION
AL
LE
VE
LR
EG
ION
AL
PL
AN
T
LE
VE
L
Calls Face to Face
-Quarterly Telecon Once a Year
Roles and Responsibilities:
- Development Pillar Leaders
- Create Minimum Standards…Consolidate Master Plans
- Speed Implementation
- Benchmark Process & BPs
Calls
Monthly Video / Telecons Calls
-Face To Face: Once a Year
Roles and Responsibilities:
- Scorecard Management
- Master Plan Consolidation
- Cases / BPs (one a month)
- Academy Completion
- Recognition
- Next Steps
Proposed Meetings – Plant AM
Pillars
Minimum schedule: Monthly 2 hrs
Maximum schedule: Weekly 1 hr.
Once a month Gemba: Mandatory
Roles and Responsibilities:
- Area Master Plan
- Review KPI and KAI
Regional
Pillar
Leaders
Plant
Pillar
Teams
AREAS AND WORKING GROUPS
AM AM AM AM AM
AM PM FII T&D EHS QM EEM OFF
Methodology Spread out from the Pillar at the areas
Raul Matt
Williams
Luca
Riva
Mahesh
Rajamani
John
Calicott
Andy
Art Dennis Oscar Patty Geoff Tina Jeff TBD
Góes
Luiz
Eric Julian
Latam NA EuropeAsia
Pacific
Non-
WovenAM Pillar Leaders
In Plant
(for this Region)
AM Pillar Leaders
In Plant
(for this Region)
AM Pillar Leaders
In Plant
(for this Region)
AM Pillar Leaders
In Plant
(for this Region)
TPM GOVERNANCE
A new TPM Assessment has been developed to help our drive for Zero Accidents, Zero Defects, and Zero Breakdowns. The assessment is based on JIPM TPM Excellence and includes inputs from ISO and CQA. It has been calibrated with JIPM. An 60% Score would be equivalent to JIPM 1st Level.
Assessing will be done by the Quality and TPM working with each plant team. It is NOT intended to be a self assessment Assessments will typically be conducted during Q4
WHAT’S NEXT?
TPM Pilot Activities
TPM Expansion (Operations)
TPM Expansion (Enterprise)
Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 Year 8 Year 9 Year 10
Development Cost Deployment Methodology & Focus on Loss Expand TPM through Insulation Business Expand TPM through Roofing Business Develop TPM Academy
Pilots in Insulation Business Pilots in Roofing Business
Pilot Activities in Supply Chain / Sourcing Launch Cost Deployment Pillar Launch Supply Chain Pillar Launch Sourcing Pillar
WHAT HAVE WE LEARNED?
Sharing and adopting lessons will speed up and increase the success ratio
• The Plant Leader defines the success • Pilot must be visible and shows business impact.
Define the pilot based on loss tree • “I don’t need more external support. I know how to
implement TPM”. BE HUMBLE and curious. • FOLLOW AND TRUST THE METHODOLOGY. No short
cut. It is a proved methodology and long term commitment
• Step 2 is after step 1 !!!! . It is not rocket science but requires discipline.
• T means Total. • Only acquiring expertise does not guarantee success
(see bullet 1 – but it does help) • Engage the union from the beginning • Communicate, Communicate ….. TPM Newsletter.
Starting with the pilot. Don’t wait for full deployment.
• Pilot can not be “too big”. Intention is to be “focused and deep” in order to gain knowledge.
• Don’t go too fast from pilot to full deployment.
• “I will stop TPM for a while because I have a rebuild (or any other excuse)”.
• Everybody like FI (Focused Improvement), but without AM we will do FI to fix and correct things and not to improve.
• No Excuses - TPM isn’t extra to everything else – it is the way we will do everything else!
• TPM is the SYSTEM
Copyright © 2016 Owens Corning. All Rights Reserved.
Q&A
Andy Maclean Director – Global TPM & Quality
Composite Solutions Business