SAINTGOBAIN GYPROC Benefits of WCM in maintenance IRIS

SAINT-GOBAIN GYPROC Benefits of WCM in maintenance IRIS Sept 2009

Results Standards Comments Agenda WCM at Saint Gobain Gyproc

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

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

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)

Results Standards Comments Agenda WCM at Saint Gobain Gypr

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

Base 100 in 2003 maintenance cost reduction together with performance improvment

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

Base 100 in 2005 even best plants still improve

Base 100 in 2005 even best plants still improve

Results Standards Comments Agenda WCM at Saint Gobain Gyproc

Results Standards Comments Agenda Benefits

Shopfloor Commitment Morning Meeting Details Plant Manager

Maintenance Step 0 – Engineering Stores 1. Risk Ranking Score Before: 126 2. Time to find Component 60 mins 3. Failure of component due to poor storage conditions 3 weeks Before 1. Risk Ranking Score After: 6 2. Time to find Component 60 secs 3. Failure of component due to poor storage conditions – never! After

Maintenance Step 0 – Engineering Stores Before

Maintenance Step 0 – Engineering Stores Before

Maintenance Step 0 – Engineering stores After

Maintenance Step 0 – Belt storage Before After

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

Maintenance Step 0 – Bearings storage Before After

Step 0 – Engineering Stores Electrical components Before After

Maintenance Step 0 – Engineering workshop Before After

Maintenance Step 0 – Engineering workshop After

Maintenance Step 0 – Engineering workshop After

Maintenance Step 0 – Engineering workshop After

Lubrication Store After

Lubrication Store Before After

Lubrication Store Before After

Lubrication Store Before After

Results Standards Comments Agenda WCM at Saint Gobain Gyproc

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 ressources focus on our internal subcontractors better controlled With operators doing AM, PM activities have gone from BM to TBM and now CBM Better involvment via teamwork, OPL, QK…

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

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)