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Maintenance Excellence at Saint-Gobain Gyproc: Leveraging World Class Maintenance Strategies

Explore how World Class Maintenance (WCM) practices at Saint-Gobain Gyproc have led to reduced breakdowns, improved standards, and enhanced performance, with insights on benefits, results, and challenges faced. Discover the impact of local cultures and unions on implementing WCM strategies.

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Maintenance Excellence at Saint-Gobain Gyproc: Leveraging World Class Maintenance Strategies

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  1. SAINT-GOBAIN GYPROCBenefits of WCM in maintenance IRIS Sept 2009

  2. WCM at Saint Gobain Gyproc • Results • Standards • Comments Agenda

  3. WCM at SG Gyproc • WCM program started on 2002 • Worldwide deployment over more than 70 sites • Focus on PM

  4. Reactive Preventive Proactive Phase 4 Seven Steps of Professional Maintenance Phase 3 Phase 2 Phase 1

  5. Benefits of WCM for maintenance in Saint Gobain Gyproc • Share the same vision, have the same targets through the global organisation • Set common high level standards and speak the same langage • Results: Less breakdowns for Less (€, hours)

  6. WCM at Saint Gobain Gypr • Results • Standards • Comments Agenda

  7. 39 machines AA at step 3 X • Planned maintenance reduce from 8h/week to 8h every 4 weeks • has been able to follow the market demand and limit the importations

  8. Base 100 in 2003 • maintenance cost reduction together with performance improvment

  9. X = 20% of machines at step 3 X Base 100 in 2003 • maintenance cost reduction together with performance improvment

  10. Base 100 in 2005 • even best plants still improve

  11. Base 100 in 2005 • even best plants still improve

  12. WCM at Saint Gobain Gyproc • Results • Standards • Comments Agenda

  13. Benefits • Results • Standards • Comments Agenda

  14. Plant Manager Details Shopfloor CommitmentMorning Meeting

  15. MaintenanceStep 0 – Engineering Stores • Risk Ranking Score Before: 126 • Time to find Component 60 mins • Failure of component due to poor storage conditions 3 weeks • Risk Ranking Score After: 6 • Time to find Component 60secs • Failure of component due to poor storage conditions – never! Before After

  16. MaintenanceStep 0 – Engineering Stores Before

  17. MaintenanceStep 0 – Engineering Stores Before

  18. MaintenanceStep 0 – Engineering stores After

  19. MaintenanceStep 0 – Belt storage After Before

  20. MaintenanceStep 0 – Belt storage After Before local clos ventilé avec système anti-poussière, Installation d'un contrôle de température et hygronométrie

  21. MaintenanceStep 0 – Bearings storage Before After

  22. Step 0 – Engineering StoresElectrical components Before After

  23. MaintenanceStep 0 – Engineering workshop Before After

  24. MaintenanceStep 0 – Engineering workshop After

  25. MaintenanceStep 0 – Engineering workshop After

  26. MaintenanceStep 0 – Engineering workshop After

  27. Lubrication Store After

  28. Lubrication Store Before After

  29. Lubrication Store After Before

  30. Lubrication Store Before After

  31. WCM at Saint Gobain Gyproc • Results • Standards • Comments Agenda

  32. What has changed in our maintenance strategy • Prioritisation based on losses and machine classification.before, try to do all machines and never succeed • Nb of subcontractors limited focus on our internal ressources subcontractors better controlled • With operators doing AM, PM activities have gone from BM to TBM and now CBM • Better involvment via teamwork, OPL, QK…

  33. Successes and difficulties • Success : • go back to basics • results • Difficulties : • ability to change to a new system • autonomy • respect standards

  34. Impact of local cultures • Germanic cultures: Long to join in, because having an existing strong system • Eastern cultures:Technological background well adapted but bad experience from window-dressing in ex-communist countries • Latine cultures:Not used to respect standards • Unions:Need to have them on board, depends on local « political » issues.(NA, South Europe)

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