Owens Corning (Guangzhou) Fiberglas Co., Ltd
Owens Corning (Guangzhou) Plant
Apply for Award of TPM Excellence in Consistent TPM Commitment

Company Profile
1. Company, Plant Profile
1.1 Company Profile
Owens Corning (NYSE: OC) is a global leader in insulation, roofing, andfiberglass composite materials. Its insulation products conserve energy and improve
acoustics, fire resistance, and air quality in the spaces where people live, work, andplay. Its roofing products and systems enhance curb appeal and protect homes andcommercial buildings alike. Its fiberglass composites make thousands of products
lighter, stronger, and more durable. Owens Corning provides innovative products andsolutions that deliver a material difference to its customers and, ultimately, make theworld a better place. The business is global in scope, with operations in 33 countries.
It is also human in scale, with approximately 19,000 employees cultivating local andlongstanding relationships with customers. Based in Toledo, Ohio, USA, the company
posted 2021 sales of $8.5 billion. Founded in 1938, it has been a US Fortune 500®
company for 67 consecutive years.
1.2 Guangzhou Plant ProfileOwens Corning (Guangzhou) fiberglas co., LTD., was established in July 1994,
located in Dongji industrial park of Guangzhou Economic and TechnologicalDevelopment Zone. It is the first production base invested by Owens Corning inChina. The factory adopts the most advanced centrifugal technology in the world toproduce all kinds of glass fiber products. Our plant occupies an area of 33,000 square
meters and has production capacity of 24,000 T/Y.

Owens Corning (Guangzhou) Fiberglas Co., Ltd
1.3 Process and Technology#Process1Batch system ：2 Materials

2Furnace system ：Gas

Mineral raw material is melted to create liquid glass at 1200 ~1300 °C.

3Fiberizing system : Gas

Melted glass flow into rotating spinners and being fiberized

4WW system : Recycled water 30~50Tons

5Binder system :13 Chemicals

6Forming system : 2 Suction boxes

Glass wool is collected onto the forming chain under forming fan suction

7

Oven & Cooling :Gas

Glass wool is heated to cure the binder and get cooled by cooling fan

8Facing system : Facing materials

Product is covered with facing materials to meet customers need

9Packing system : Packing material

Product is wrapped up by packing materials to meet requirements

Description
Mineral raw material is weighted and mixed then sent to furnace.

Flush the forming chain and forming suction duct with water, the water is recycled to mix withbinder
Binder is applied to the fiberglass through binder rings

Cullet is melted in furnace with borax, the molten glass flow into the rotating spinnerand being fiberized, the fiber is collected by forming suction on the forming chain,during this process binder is applied on the fiber, then the fiber is sent to the oven forcuring, cured fiber pack is cooled, then trimmed and chopped to desired size, finallythe product is packaged and sent to warehouse.
1.4 Plant Organization Chart

This is the organization chart of Guangzhou plant. At present, we have 85 employees.
On this organization chart, newly changed positions are marked with red starcompared with 2 years ago.
2. Milestone on the Journey of TPM Excellence
2.1 Why we keep doing TPM
Through the implementation of TPM from top to bottom in the plant, TPM has
become culture of our company. It is the way we operate our plant. All employees
attend in activities. Talent growth activities and TPM incentive policy make people’s
attitude and skill improved significantly, all these bring operation excellence to ourOwens Corning (Guangzhou) Fiberglas Co., Ltdplant. Great change of shopfloor environment also gives people who work in thisplace a more comfortable and safer experience, Employees are proud of working here.

We applied for the Award for TPM Excellence (Category A) in 2020 and was officiallycertified in early 2021. We are proud of it and take it as a new start for our TPM journey

2.2 TPM Journey in Guangzhou Plant
Guangzhou plant has taken TPM as the policy of operation and management from2016.
In 2017, launched FI, AM, PM, T&D pillars and 4 pilot areas were rolled out.
In 2018, 90% areas had achieved AM step2, zero break down projects were initiated,
QM, EM, OA, EHS pillars were also launched.
In 2019, we focused on site improvement which aimed to reach AM step4 for all areas

Owens Corning (Guangzhou) Fiberglas Co., Ltdand TPM methodology training upgrade.
In 2020, 90% areas passed AM4 assessment.
In 2021, 100% areas passed AM 4 and 22% areas passed AM 5 assessment.
In 2022, all areas passed AM 5 and 22% areas passed AM 6 assessment.
3. Benefit Achieved
3.1 Tangible Benefits
Since we kicked off TPM in 2016, all aspects of plant operation have been improved
significantly. The main operation indexes are as below:Owens Corning (Guangzhou) Fiberglas Co., Ltd
Improvement ProjectProjectProject Name

Expected Benefit

Annual Benefit

Project Leader

GZ-1

Laboure savings

Reduced overtime cost about 35 K$37

Zeng Leo

GZ-2

Oven NG consumption optimization

0.076 Tce/T reduce to 0.069 Tce/ton

53ThomasGZ-3

Reduce Furnace NG consumption

Calorific value:2909 KWT/T reduce to2718KWT/ton

145

Chen bin/ThomasGZ-4

Reduce electricity consumption inFacing area

Reduce 40KWT/ton

63

Chen bin/Thomas

GZ-5

Reduce line breakdown time

Breakdown loss reduce 10 hours

9ThomasGZ-6

Optimise planning and reduce theproduct change cost

Efficiency increase 5%

9Cui Yatao

GZ-7

BAE improve 0.5%

From 82% to 82.5%

11Chen bin

GZ-8

Spinner effeciency improvement

From 90 tons/ea to 100tons/ea

26

Chen bin

GZ-9

Scrap improvement

From 10tons/month to 7tons/month15

Chen bin

GZ-11

Facing effeciency improvement 0.2%

From 97.6% to 97.8%

10

Chen bin

GZ-12

MRO

3 diesel forklift change to electric forklift

33

Ray Huang

GZ-13

Labor efficiency

Fiberglass kg/manhour from 82 to 85

89

Zeng Leo

GZ-14

Process energy opitimization by unit
Elec consumption reduction

Reduce 10 M3/ton

9Chen bin/Thomas

GZ-15

Process energy opitimization by unit
NG consumption reduction

Reduce 2 KWH/ton11

Chen bin/ThomasGZ-16

Bushing efficiency improvement

Number of bushing using reduce from 20 to 10

10Chen bin

3.2 Intangible Benefits
Through continuous implementation of TPM, the working environment is getting
better, the skills of employees are constantly improved and expanded. Employees
have a deeper understanding of process, quality and safety after participated TPM
activities. the morale, customers' satisfaction, competitiveness of product even imageof our company is also greatly improved.
4.1 Experience & Gains
Plant operation has been improved comprehensively since we kicked off TPM in2016. Plant ensure the successful TPM implementation through four aspects as below.
100% leadership and engagement are the basics for all pillars’ success.
Integrated TPM into Daily Management
Align objectice through policy deployment
Communication cross pillars
Achieve saving through loss tree development
Problem solving through TPM step approach
People growth throgh skill matrix
SQDCEPM tracking

Learning by Doing
20% class traning, 70% practice and 10% lesson &learned
TPM boot camp
Pilot machine
On Job training
Benchmark & Sharing

How toEnsureSuccess？

Plant Management Commitement
Resources support and allocation
Monthly TPM steering meeting
Tagging & De-Tagging everyday
LPA (Layered process audit) everyday
Mentor & Coach TPM small group
Recognition and feedback

People Growth and Recognition
Owenership and engagement
Skill matrix
Small group activity
TPM best group
OPL (One point lesson)
Pillar specialist development
Multi-skill personnel trainingOwens Corning (Guangzhou) Fiberglas Co., Ltd
4.2 Future Plan
Set plant operation’s core objectives on loss and cost reduction and achieve them bydeeply using TPM methodology.
Launch more improvement projects through the upgrading of personnel skills and theimprovement of AM ability.
Use advanced technology to eliminate potential risks of our machine to achieve zerobreak down and prolong machines’ service life in all areas.
Use EM methodology in all new projects and new products.
5. Achievement Record
CategoryS
S
PPP
PP
PP
P
Q
Q
QCDDS
MIndex(Calculation Formula)
Number of work-related accidents
requiring days off work
Number of work-related accidents
not requiring days off work

Unit

Last time awarded
2020

Actual Status
2023

Cases/ year

10Cases/ year

10Productivity for main products

Tons/Operator hours

0.062

0.064%

95.0

95.6%%%Breakdowns/ year
Hour
Hour
Number/year
%

97.7
97.9
99.3
67
110
4220.69

97.8
98.3
99.5
57
12030
00.48%

0.69

0.48

--

5.5
100

2.71
100

0.30

0.00

321

388

OEE
(or Overall Plant Efficiency)
Availability
Performance Rate
Quality Products Rate
Number of breakdowns
MTBFMTTR
Number of customer complaints
In-line defect rate, scrap
In-line defect rate, scrap andrework

Cost/Unit
Cost index
Cost/Kilogram
Production Lead timeDays
Delivery performance%
Accidents per 1,000,000
Safety index
operator hours
Number of Employee Suggestions
Number/year