Armacell Case Study

World Class Manufacturing (WCM) Programme

Global manufacturer

Insulation products

The support from Henkan is contributing to speed up and reinforce our program. I want to mention the cooperation with John C. for the senior Auditing process which represent the key frame to keep consistency and pace. His wide WCM competence and open mind approach made easy the model alignment and effective the feedback.

Roberto Mengoli

Chief Technology Officer

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Client

Armacell is a global manufacturer of advanced insulation and engineered foam products. The company has more than 23 plants in 16 countries on 4 continents.

Scope

Armacell has embarked upon a World Class Manufacturing Programme entitled ‘World Class Armacell Mind-Set (WAM). The initial focus of the programme has been to apply ‘Focused TPM’ globally across its facilities and then start to apply ‘Lean’ methods to its supply chain.

Aims

To create a world class manufacturing organisation in terms of plant performance through the application of WCM improvement methodologies and the effective engagement of the workforce.

The initial focus was aimed at improving plant reliability restoring the basic condition of the key equipment across the entire 23 manufacturing facilities. In doing so this would effectively reduce the variances in the process due to the equipment and give the possibility to focus on Material, Methods and Man and have a more stable production process with beneficial effect in material loss reduction.

Background

The WAM Programme is based upon WCM (TPM/QC/Lean) methodology. Armacell launched the programme with the initial focus on their larger strategic multiproduct plants. The WCM methodology was seen as the most appropriate approach for the challenges the Armacell have to overcome.

WCM is a proven methodology that has been adopted by many companies who processes are machinery/ capital intensive and require a proven approach to engaging the workforce as a whole to improve manufacturing and supply chain performance.

Approach

Henkan team members have been involved in the WAM Programme at both site and corporate level

Henkan have been engaged by Armacell from both a consultancy and training perspective. In terms of consultancy this has involved the development of some of the WAM models (tools and techniques) including Autonomous Maintenance, Professional Maintenance, Early Equipment Management and Early Product Management.

In addition to supporting the model development Henkan also deliver the associate training at site level. Generally this is done in the form of ‘Practitioner Courses’. The courses are delivered with a balance of theory and practice. Most exercises are ‘real’ being based at the Gemba making improvements that have a direct impact on business performance. Following successful attendance of the courses delegates then apply the tools and techniques they have learnt as Practitioners.

Henkan also provide direct support of global corporate auditing events at individual factories in all regions. These 6 monthly events are attended by the Armacell senior management team as well as Henkan. These events include an assessment of the status of WAM maturity against a predefined set of criteria and also provide an opportunity to coach the local teams on the implementation of tools and techniques.

Results

All the relevant sites are currently included in the programme, and a systematic Audit Calendar has been implemented and followed driving the organisation vs the excellence. Visible improvement in tools implementation, standard level and competence is shown across the organisation with tangible evidence in the operational KPI.

From the TPM standpoint the basic step 3 has been implemented in all the main sites starting from the model area and has now horizontally expanded across the key machines bringing to 0 BD due to lack of basic condition and lack of PM.

Testimonial

“The support from Henkan is contributing to speed up and reinforce our program. I want to mention the cooperation with John C. for the senior Auditing process which represent the key frame to keep consistency and pace. His wide WCM competence and open mind approach made easy the model alignment and effective the feedback.”

Roberto Mengoli – Chief Technology Officer

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