Implementing TPM increases technical availability as a whole

Audi Brussels was founded in 1949 as part of the German Audi group and has since then been actively involved in the production of various Audi models. At the moment, the A1 (the smallest member of the Audi family) and the S1 are being produced in the European capital in an area of 540,000 m2. As a result, Audi Brussels is fulfilling an important role within the Audi group as a production site.

The facility in Brussels can rely on a highly qualified team of workers with extensive experience. In 2015, over 110,000 vehicles rolled off the production line at Audi Brussels and the company employed approximately 2500 members of staff.

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Project definition and goals

Audi is busy optimizing the production process in the Assembly department at Audi Brussels in order to see its expansion into one of the most productive sites within the Audi and Volkswagen group. There has been a culture of continuous improvement at this factory since 2010, but in order to continue being one of Audi's most successful sites, new methods were needed.

Project approach

One of the methods used is Total Productive Maintenance (TPM), a tool which PDM helped to implement at the start of 2014 to improve the availability of the systems and prevent unnecessary work from being carried out. Responsible for the management of this tool are project groups consisting of employees from production, maintenance, and planning. They meet daily or weekly to discuss the themes for improvement. This has enabled employees with a range of different expertises to come together to collaborate. In order to secure the success of the TPM method, it was also necessary to manage behavioural change.

Project results

  • Vast improvements have been made since TPM was first implemented. Maintenance workers have noticed that they have fewer operational tasks. The time they previously spent troubleshooting malfunctions can now be used to make continuous improvements and analyses and introduce new technologies.
  • So far, more than 500 themes have been completed and there has been a dramatic fall in the number of different machine malfunctions. This has led to a significant increase in technical availability as a whole within eighteen months, making it possible to produce more vehicles per shift than before.

The improvements made as a result of TPM are showing an increasing trend.

Jan Note
External TPM adviser for Assembly at Audi, on behalf of PDM

TPM is regarded as being the catalyst for a culture of continuous improvement. It requires a lot of effort, and action to be undertaken, even when things are not going so well. PDM is accustomed to taking the lead in this regard.

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