Banpu Milestone Success

Banpu Site achieves first top Operations Excellence Award -
Minimising Operational Risk in Mining & Process Industries through the Business Improvement Strategy of TPM & Lean (TPM³)
Banpu 'The Asian Face of Energy' is a Thailand energy company with coal mining operations spanning Thailand, China, Indonesia and more recently Australia following their purchase of Centennial Coal in September 2010. Banpu is now referred to in the local media as Asean's largest coal miner.

In 2002 Banpu decided to use the Japanese developed Total Productive Maintenance (TPM) methodology as its Business Improvement strategy to minimise its Operational Risk along with maximising its current capacity, minimising coasts and most importantly creating a safe and productive culture at its mine sites. They choose their Lampang Open Cut Mine in Thailand as the pilot site. In 2004 the Lampang site realised the Japanese had very limited knowledge about mining and appeared hesitant in allowing their site to apply for the Japanese TPM Excellence Award - an improvement goal set by the CEO.

After researching the internet, they approached CTPM Australasia who had developed an Australasian approach to TPM in 1998 which they called TPM³ to distinguish from the Japanese version, and had been successfully using their approach in a range of mines within Australia. In 2002 CTPM had developed a 5 Level Milestone TPM³ Excellence Award which Banpu saw as a critical element in getting their sites to strive for World Class Performance in business improvement and thus minimising their Operational Risk.

Banpu has recognised for a site to become World Class it needed 3 imperatives in place:

an external, internationally recognised, 'Gold Medal' to strive for (5 Level Milestone TPM³ Excellence Award as the Improvement Vision for the site);
a great coach with a proven training & development plan covering all employees that spanned 3-5years (TPM³ Master Plan spanning 15 cycles / 5 years); and
a process to establish the discipline within the site to follow the proven training & development plan (team approach progressively engaging all employees).

CTPM's initial audit in 2004 at the Lampang site verified they were at Level 2 status and over the following 3 years they advanced to become the first site in the world to achieve Level 5. The impact on performance at the time of the Level 5 verification audit in May 2007 was that the site had achieved 517 days accident free and reduced average maintenance cost by 50%. Read more...

Trainer Number:
91301

www.ntis.gov.au