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Award System
1. Introduction 3
3. Killer Criteria 5
Driving System 7
Safety Pillar 26
Introduction
This is a guide is to provide Brewery Management teams that are challenging for the Bronze
TPM Certification Award information on the criteria and practical guidelines on what a
Bronze Brewery looks like The Bronze Certification Award is directly linked to the Heineken
TPM Roadmap and recognises a Brewery progressing from Expansion Phase to
Stabilisation Phase (Sustain and Expand to Brewery Logistics, Brewing and Utilities).
Customer Satisfaction 50
Social Responsibility 85
Quality 55
6-8 Zero Losses examples for FI, AM, PM, PQ, T&E, Safety
The Shop Floor Excellence element of the Killer Criteria is reinforcing restoration of basic
conditions with respect to AM, PM and 5S activities.
Introduction
The Driving System sets the priorities derived from the HMS and GTF and examines the
close the loop system (PDCA). Based on the most important KPIs clear loss deployments are
made by the Pillars to loss mode level. Then TPM (e.g. teams / kaizens) and non TPM
activities (e.g. investments) are planned, monitored on a monthly basis and countermeasures
taken when the planned actions are not filling the gaps.
For the Heineken Bronze TPM Certification Award breweries will have to achieve a minimum
audit score of 78% (level C) for the Driving System. The Daily Control System (DCS) is
effective for all Pillars, 80% of HMS KPIs are under TPM activity and 75-90% of teams /
kaizens achieved results OTIF.
1. Concept
Heineken Management Systems are in place and reporting is OTIF.
HMS, GTF and BCS is 100% reported OTIF (quality and quantity).
80% of HMS KPIs is under TPM activity. This means the Pillars are looking after the
Loss Deployment and Team Planning to close the gap.
All savings related to TPM and non TPM activities are measured and reported and
linked to GTF.
2. Process
The Close the Loop System (PDCA) and the Daily Control System is being managed
and is effective to ensure the achievement of targets and to hold the gains respectively.
Target setting is cascaded from GSC to Regions, OpCos, Breweries and
Departments.
There is a clear loss deployment to loss mode level for the most important KPIs. This
supports the vision and potential improvements.
A Project plan to Close the Gaps is in place.
Follow-up of the project plan is done on a quarterly basis with clear countermeasures.
The most important KPIs are monitored on a monthly basis.
The Daily Control System is effective for all Pillars. This means the shop floor
management and daily control of PIs for all processes in the brewery.
3. Results
As a result of the effective Driving System process targets for HMS and GTF are being
achieved OTIF.
In addition to the standard assessment of achievement versus target YTD, 12 months
HMS absolute will also be verified.
Introduction
Organisation & Change Management is examining the on going adjustment of the brewery
using the TPM methodology and embedding the learning in management systems. This
means that there is involvement at all levels of the organisation from shop floor to
management by active participation in teams, kaizens, RCFAs to drive loss reduction.
Continual training and development of all stakeholders is of utmost importance and
leadership is crucial for a successful implementation.
For the Heineken Bronze TPM Certification Award the brewery will have to achieve a
minimum of 78% (level C) and support from Pillars to teams and kaizens is effective and
standardised.
1. TPM Organisation
Use of TPM tools is becoming routine on a daily basis, aligned and integrated in all
brewery activities, being driven by top management. The Steering Committee is
continually reviewing (PDCA) the progress of the implementation particularly the
barriers to change to take the brewery to the next level.
Vision and mission to next level. 3 year vision has been developed on Brewery KPIs
and organisational development (personnel at all levels) exists and are consistent with
OpCo vision and agreed in steering committee. Vision is reviewed in line with
milestones; phases of TPM and new challenges. Description of the impact of the
vision on system, structure & people in Brewery
There is a Single Agenda Meeting structure; this means TPM is aligned and integrated
in all meetings.
One Master Plan (TPM and non TPM activities) is visual and communicated to all
levels in the plant.
The Daily Control System is effective for all Pillars with clear roles and responsibilities
for the management team and shop floor.
Internal auditing is a key element in driving change and implementing the
management system of TPM as a way of working. The key aspects of auditing are to
ensure that all activities are aligned with the brewery strategy and priority. The speed
of implementation and quality of activities are at the right level and that robust systems
are in place to ensure sustainability. In addition to checking and verification, auditing is
also a form of coaching, consulting and training for the Pillar and line teams. All of the
6 main pillars, driving system, organisation and change management and team Audit
Systems are in place with clear action plans and escalation to the Steering
Committee for high level blockers.
Regular SWOT or CEDAC (Cause and Effect Diagram with the Addition of Cards) is
performed with the steering committee and action plan is in place.
2. Involvement
There is involvement of staff at all levels with active participation in activities such as
teams, kaizens, RCFAs and tagging. All staff are continually being trained and
developed to support them with their new roles and responsibilities.
There is regular communication of the TPM programme and the HMS results to all
staff in the plant.
There is a plan in place and executed for the development of Pillar, Team Leaders
and Members and Shop Floor Trainers.
PKEs are being actively used for training, coaching, mentoring and auditing of
teams.
Involvement of all staff is monitored on a monthly basis for participation in teams,
kaizens, RCFAs, DCS, tagging. This is registered in BCS OTIF.
A plan is available for the integration of existing systems i.e. ISO, HACCP, OPLs,
SOPs.
Shopfloor personnel are empowered to perform autonomously improvement actions,
analysing and solving issues that affect workplace standards.
There is a control system in place to assess the effectiveness of peoples activities
at shopfloor level. Team leaders/supervisors continuously define plans to ensure the
close the loop system with regards to subordinates actions.
3. Level of Approach
There is a balanced approach across all pillars to manage resources for loss reduction
activities; for teams, kaizens, RCFAs and the DCS. There is continual horizontal
expansion of good practices inside the brewery and also good practices are being
shared and implemented from other breweries to prevent reinventing the wheel
The brewery is a safe place to work, is clean, tidy and well organised.
Loss reduction activities such as teams, kaizens and RCFAs are fully aligned with
the strategy and priority. Planning of activities is based on the benchmark of 0.4
teams / kaizens per FTE and 5 RCFAs per FTE and the breweries capacity to run
and manage these activities.
Operators and Technicians are initiating the RCFAs and kaizens from the Daily
Control System.
Breweries shall have a system in place that systematically reviews approved good
practices in HeiQ and records the discussion of implementation, including outcome
and follow-up if applicable, is discussed at every SC meetings, proven through its
minutes. The TPM coordinator reviews global audit reports to proactively look for
potential good practices, also to be discussed during SC meetings. The brewery is
also active in uploading examples (minimum 2 per quarter) to the TPM eRoom and
good practices (all identified during GSC Audits) are uploaded to the HEIQ.
5S
5S is the foundation upon which we lay other improvements. Good communication via clear
and precise area and machine boards should be in place. The importance of order, good
layouts and how clean things appear is secondary to the importance of everyones attitude
toward cleaning and 5S implementation. Within 5S, the two most crucial elements are the
first two, simplify and separate. The success of improvement activities depends upon them.
The brewery needs to have a strategy in place to implement 5S, with hands-on
activities taking place on the shop floor. Conditions need to be as visual as possible. So
that everyone can see how to maintain the proper conditions.
S1, Simplify. Clearly distinguish needed items from unneeded items and eliminate the
latter. The main strategy for implementing this step is the 5S (red) tag strategy. It is a
visual method that makes identifying waste easier.
The brewery shall will have a record of red tags implemented and solved for 5S
purposes.
S2, Separate. Keep needed items in the correct place to allow for easy and immediate
retrieval. All personnel will be able to easily understand how things are kept in the
factory. The signboard strategy is a visual method that helps operations run smoothly
by enabling anyone to understand where things go.
Every brewery shall maintain proper signboard strategies , indicating the kind of
equipment being used and where, what, and how many inventory items are to be
kept. Signboards should only be used for items that are needed for current production
purposes, therefore it needs to be preceded always by the red tag strategy.
S3, Cleaning. Keep the workplace swept and clean. The brewery shall have cleaning
activities integrated into daily operations (CILTs) and maintenance tasks to combine
cleaning checkpoints with maintenance checkpoints.
S4, Standardise cleanup. This is the condition the brewery supports when maintaining
the first 3 Ss. The breweries will have assigned responsibilities for the first 3 Ss,
integrating those duties into regular duties and continuously checking on the 3S
maintenance level.
S5, Sustain. Personnel shall always follow specified (and standardised) procedures,
proven through the execution of weekly 5S audits, recorded by means of checklists and
dividing each department into manageable areas. Audits shall be performed by team
leaders/supervisors along with SC members.
5S is thoroughly promoted within the brewery, with the brewery manager taking an
active role.
5S is completed in packaging, workshops, lubrication and production stores. This
includes a robust audit system which integrated with safety and hygiene.
5S is in progress in the rest of the plant; brewing, utilities and warehouses (3rd step
completed).
Visual Management
Visual management constitutes an integral part of TPM success. Problems should be made
visible in the workplace. If an abnormality cannot be detected, nobody can manage the
process.
Visual management makes abnormalities visible to all employees managers, supervisors
and workers so that corrective action can begin at once, helping both workers and
supervisors stay in direct contact with the reality of the shopfloor.
The brewery shall make any abnormality based on the 4Ms displayed visually.
Man
A suggestion system for operators is in place.
A display board shows who is trained to do what tasks, and who needs additional
training.
SOPs are displayed throughout the shopfloor.
Machine
There are systems in place, eg poka-yoke, that stop the machine immediately after
something goes wring.
CILTs and Q points are visually displayed in all applicable sections of the
equipment.
Metal housing replaced whenever possible by transparent covers so that the
operator can see when a malfunction occurs inside the machine.
Materials
Storage of materials near or off the equipment area should be indicated in the
machine board.
The storage areas should have fully implemented 5S, including stock levels (re-
order points) and part numbers. Different colours should be used to prevent
mistakes.
Method
Standard worksheets are posted at each workstation. They not only remind the
operator of the right way to do the job, they also enable supervisors and managers
to determine whether the work is being done according to standards.
The standards show sequence of work, cycle time and quality checkpoints. They
also need to define abnormalities and then outline the steps to follow in response.
There is a clear link to DCS. Daily production targets should be visible, displayed
on the machine board alongside the actual figures. This information alerts the
supervisor to take the appropriate corrective measures.
The FI Pillar contributes to the definition of the improvement strategy through development of
OPI, Volume, Productivity, Cost Model and Gap Analysis. Also the FI Pillar develops the know-
how and supports teams to improve on specific machine losses (set up time reduction) and
labour productivity.
FI is also responsible for the Driving System process, attacking losses and setting the standards
for holding the gains.
1. Loss Deployment
A Loss Deployment system is in place to manage the improvement strategy.
Loss analysis for the most important Brewery KPIs is deployed to loss mode level.
There is a clear link between KPIs and Pillars and a clear plan to close the gaps (TPM
and non TPM activities).
There is a production cost deployment in place with clear priorities.
There is a savings calculation in place.
6. Organisational losses
An Organisation Loss system is in place to manage the improvement strategy.
There is a clear record of activities (monitoring) carried out by ALL staff when production
is stopped.
A strategy is defined for use of non production time (standards are available for indirect
tasks).
There is evidence of continuous reduction of organisational losses.
The Planned Maintenance Pillar strives for increasing the brewery performance (unplanned
downtime) and effectively reducing maintenance costs. This is done by eliminating breakdowns,
minor stoppages and developing a cost effective planned maintenance system. The PM pillar
also has a key role in developing the skills of the operators to implement first line maintenance
(CILT) so giving more time for the technicians to do real planned maintenance and improve
systems, processes and machines.
1. Organisation
There is a professional maintenance organisation with clear roles and responsibilities with a
balanced approach to loss driven and critical equipment.
There is a Single Agenda for maintenance. This means the PM Pillar and existing
maintenance system (e.g. TBM, planning of overhauls, eradication of problems) are fully
integrated.
The maintenance organisation drives continually Zero Breakdowns, Zero Minor
Stoppages and Reduced Costs (a cost reduction long term plan is in place). Four (4)
examples of zero losses per quarter are required.
There are clearly defined responsibilities for:
Support Autonomous Maintenance, Zero Breakdown Activities, Zero Minor
Stoppages Activities, PM and CBM Systems, 5S in Workshops and Spare Parts
Stores, Cost Management, Information Systems and People Development.
Support tag management and reinforce tag analysis as a feedback loop on AM and PM
activities and as a tool to reduce overall CILT time.
Abnormalities (feedback loop).
Sources of dirt and contamination / difficult to access areas (overall reduction of
CILT time).
7. Cost Management
A System is in place to monitor and target all costs; spare parts, direct and indirect labour
which is in line with brewery focus and strategy.
Cost reduction is achieved through sustainable improvements i.e. Improved spare parts
turn-over and stock ratio, contractor management.
9. Information Management
The maintenance information is well documented and organised for reporting purposes
OTIF.
There is a good administration of maintenance information; budget monitoring, manuals,
drawings, RCFA records.
The AM Pillar involves an important change management process for the people and the
machines. AM develops the system to restore basic conditions, maintain conditions and
then to improve the machines in the brewery. This is done by developing the people and
enabling the production personnel to take care of their machines by creating ownership.
Also AM influences the attitude, values and behaviour of the people to continually enhance
the condition in which they work creating the base and the resources for performance
improvement. Zero loss culture is visible. The AM Pillar also addresses the high level
blockers/obstacles preventing successful AM implementation.
2. CILT Standards
The CILT standard is the key vehicle for incorporating all maintenance
improvements from teams, kaizens, RCFAs etc. This is important for
sustainability.
CILT standards are fully implemented where step 3 is completed. There is one
standard for CILT in use in the brewery.
CILT standards are verified by PM in order to avoid mistakes. CILT includes safety
aspects. The countermeasures effectiveness for CILT audits is >90%.
There is ongoing development of CILT standards even after step 3 and there is a
clear link with the output from teams, kaizens for sustainability tasks required.
The AM Pillar team is also actively reducing the overall time required for CILT time
across the brewery site. This is achieved through horizontal expansion of
improvements, on going training and visual management.
Heineken rules, standards and procedures (basic conditions) for all equipment and
processes must be respected. The most important standards and procedures to be
respected are the HOC quarterly audit (including 5S, AM audits), the equipment
standards and process procedures relating to brewing, utilities and packaging.. The
cleanliness & hygiene audit and reporting is in place, performed regularly and
Available time and resource is also a key factor for restoring basic conditions with
respect to cleanliness & hygiene. Therefore the AM pillar also has to lead activities
in order to make cleaning easier through better tools, improved access, visual
management, removing sources of dirt and contamination etc.
The AM Pillar also has to continue discussion with line teams the best way to
maintain basic conditions with respect to cleaning and hygiene to achieve the same
level as the model machine.
Actual condition of machines are good including cleaning (no leakages, no excess
grease, no broken parts).
4. Tag management
A tag management system with feedback loop (including procedure) is in place OTIF.
Systematic analysis, prioritisation and clustering of tags (by function and type) to
maximise efficiency on all AM teams is routine.
Tag completion is quick, systematic and ; average response < 2 weeks. The
countermeasures effectiveness for tags is >90%.
The improvement tag ratio clearly shows an improvement oriented attitude of the
line workers to improve the condition of the brewery.
Tag analysis provides data for common failure modes for reviewing AM and PM
standards.
5. Operator Development
Together with T&E the AM Pillar and team steps facilitate the changing role of the
operator; from operator to technical operator and owner of the machine. Therefore a
Training and Development plan is in place to enable operators to perform AM team
steps 1-3.
Via the training and practical application of Step 1-3 the operators can clean the
machine effectively (same standard as model machine), make a total clean out, and
identify abnormalities, sources of dirt and difficult to access areas (issue tags).
They also have the ability to make simple machine improvements (answer tags),
create, execute and continually update CILT.
Support machine performance improvement by assisting minor stoppage reduction
(MTBT) via the sampling method (MTBA for brewing) by a systematic approach by
operators. Breakdown reduction by providing what happened information and
assisting in the analysis (RCFAs). Losses due to MAN and method are shared with
the T&E.
AM team leaders are developed from the shop floor to support the roll-out of AM.
Champions are identified and developed for future trainers, pillar members.
8. AM in DCS
The Daily Control System by operators will support the operational aspects of AM by
being the forum ;
Monitoring of CILTs (CILT time), # of breakdowns due to lack of CILT, # of
breakdowns analysed, CILT audits
% Tags removed and tags removed by operators
Daily/weekly overall OTIF trends for MTBF, MTBT, MTBA in brewing (where
applicable) are in place and analysis is ongoing. Q Points OTIF (where applicable)
Trigger points for ongoing investigations from the ongoing and closed
teams/kaizens/RCFAs. Zero losses (6-8 examples)
Machine/Line/Area boards are in place capturing the key information.
The T&E Pillar ensures skill development in accordance with the strategy, priorities and
targets (KPIs) of the brewery. Proactively it has a supporting role to all Pillars and the
responsibility for skill assessment (gap analysis) and development for all functional areas. It
facilitates the behavioural changes in roles (e.g. AM) and leadership development.
Reactively it focuses on loss reduction with the systematic collection of losses due to man
and method from all Pillars.
5. Training Infrastructure
The T&E Pillar should build an infrastructure to support the development of
people and the new way of working in TPM. The infrastructure should
include both a training facility and systems such as training material and packages.
There is a training facility (room) used in a practical way to support the ongoing
training and development of not only Operators but also Mechanics and Electricians.
Training packages such as manuals, training aids including machine parts,
simulations jigs, videos, practical exercises are in place to teach operators how to
perform AM steps 1-3; how to clean, lubricate and inspect. Attention is also paid to the
behaviour aspects by coaching and feedback from the Team Leaders.
Shop floor trainers are identified, trained as Trainers and actively carry out shop floor
training. (Operational training / 5S, 5WHY, CILT etc).
A system is in place to manage the horizontal expansion of documentation OPLs and
SOPs.
7. New employees
Induction training, including TPM methodology and tools is important to communicate
the TPM way of working in the brewery.
An introduction training package is available for new employees
including TPM as a way of working for new employees.
9. Zero Losses
Zero Loss system is in place to manage the improvement strategy and support loss
eradication.
Zero loss culture is visible (6-8 examples). This is monitored by operators on the
machine board where applicable.
The PQ Pillar is to develop and support the zero defect system. The PQ Pillar drives the
brewery into the systematic process of loss eradication. It switches the mindset from product
quality control to process control and then to an efficient conditions management system to
hold the gains.
1. Customer Complaints
Customer Complaints system is in place to manage the improvement strategy.
Customer claims are fully deployed in a systematic way with root cause and 4Ms
defined.
2. Waste Reduction
Waste Reduction (extract & packaging losses) system is in place to manage the
improvement strategy.
80% of waste is fully deployed in a systematic way using the materials balance
methodology and clear priorities are defined.
Improvement teams / kaizens are constantly working on waste reduction in line with
the plant strategy and priorities.
3. Compliance with Heineken rules, standards and procedures from GSC Polices to
restore basic conditions on processes and system.
TPM is aligned with GSC Policies i.e. Rules, Standards & Procedures in the
HEIQ. This is critical for the restoration of basic conditions for the processes and all quality
systems.
There is a systematic (once per quarter) compliance check in line with GSC Policies
requirements and there is an action plan to follow-up on non compliance.
6. Zero Defects
Zero Loss system is in place to manage the improvement strategy and support loss
eradication.
Zero loss culture is visible (6-8 examples).
The Safety Pillar is to develop and support the zero accident system. It assures workplace
safety and supports a good working environment for all staff in the brewery. The Safety Pillar
focuses on risk identification, risk assessment and risk reduction to support zero accidents.
Zero Loss culture is visible (3-4 examples per quarter).
1. Promotion
There is continual attention to Safety by awareness campaigns to create a safe working
environment.
Events and promotions have been carried out to increase the visibility of safety in the
plant and the safety awareness for the staff at all levels. This also includes contractors.
Safety is included in the induction programme for new employees and contractors.
2. Involvement
Employees are allowed the opportunity and time to leave the production/process/job task
to participate in the H&S activities, meetings, etc.
Employees and management participate in setting the safety goals. Employee input
should be solicited for development of the brewerys safety goals. Examples include use
of survey results, Safety pillar, and/or committee. Brewery improvement needs should be
included in the safety goals.
3. Tagging
There is Safety tagging system in place and linked to AM to create a safe working
environment at shop floor.
Safety tagging is clearly visible. An overview of the number of safety tags per month is
available. Safety tags are managed in a prompt and efficient manner.
4. Risk Assessment
There is Hazard Identification, Risk Assessment and Risk Reduction workplace system
in place for the improvement strategy.
There is a roll-out plan in place systematically performing machine risk analysis.
7. Compliance with Legal and Heineken Safety rules, standards and procedures.
TPM is aligned with local legal requirements and GSC Policies in the HEIQ.
There is a systematic compliance check and action plan to follow-up on non compliance.
Application
Breweries can apply to progress to the Sustain and Expand to Brewery Logistics, Brewing
and Utilities Phase and for the Heineken TPM Certification Bronze Award at the start of the
year as part of the target setting process. This is agreed with the RSCD and Global TPM
Manager.
The mid year Audit will be a pre-assessment. The Auditor, Brewery Manager and Regional
TPM Manager will review the Certification Criteria to confirm that the brewery is ready to
proceed with the Heineken TPM Certification Bronze Award audit at the end of the year.
Usually during pre-assessment requirements for HMS should be achieved (based on data
in BCS). If not, and there are more than 6 month to the final audit, brewery has to present
plan to achieve and maintain results not later than 6 months to the final audit.
Brewery should perform a gap analysis on criteria of Bronze TPM Certification Award
and prepare action plan to close the gaps.
The end year Audit will assess the 3 elements of HMS absolute score, TPM audit score
and killer criteria. This will be performed by Senior Auditors and the result announced at
the closing meeting.
Audit
The audit should be 70% based on the shop floor auditing and visiting teams and activities.
The Bronze Certification Audit is typically lasting 1.5 2 days and is conducted in the
normal way with Brewery and Pillar overviews and auditing of shop floor teams. The
introduction and presentation should each last approximately 30 minutes including strategy
and priorities linked to Brewery strategy and priorities. Also confirm alignment and cascade
from FI Pillar, Masterplan, highlighting key milestones and steps, strategy into action,
examples of Pillar activity by Pillar step, teams / activities plan. Team/Kaizen planning
strategy versus Brewery strategy, priorities and losses and Brewery team target of
0.4Teams/FTE/Year Teams closed since last audit and planning for next 6 months.
Evidence of activities related to the Bronze Certification criteria must also be presented.
Certification
The Bronze TPM Certification Award will be presented by the GSC Director and Global
TPM Manager at a ceremony.
Audit Agenda Example Brewery Tour and Shop Floor Team Audits