Pittsburgh Corning (Yantai) Insulation Materials Co., LtdAward for TPM Excellence, Category B
1. Company and Plant Profile
1.1 About Owens CorningOwens Corning is a publicly traded company on the New York Stock Exchange (NYSE: OC), theheadquarter based in Toledo, Ohio, posted 2021 sales of $8.8 billion and current
employs about 19,000 people in 33 countries around world, founded in 1938, an
industry leader through three major business units include Insulation Solutions
Business (ISB), Roofing and Asphalt (R&A), Composites Solutions Business(CSB) to serve the market, has been on Fortune 500® list for 67 consecutiveyears.
Our products range from Glass Fiber to Foamglas, Mineral Wool and otherhigh-performance products and systems dominated in transportation, electronics, marine,infrastructure, wind energy, LNG etc. specific markets for residential, commercial and industrialapplications. Now, OC has become a Broad-Based Company Recognition, we aspire to build
market-leading businesses; global in scope - human in scale.

1.2 About Yantai Plant
Pittsburgh Corning Yantai plant is located in No 26, Kaifeng Road, Yantai Economic
Technological Development Area (YEDA), Shandong Province, China. Plant Phase I project oncommercial from March 2015 with primary focus on Foamglas materials production (the FLATworkshop). Phase II project on stream from Dec 2016 with primary focus on Foamglas materials
post fabrication (the FAB workshop). The plant main information listed in below table.
Main information

Plant
FLAT workshop

FAB workshop

Occupied area

100,000 m2

Initial plant investment$65 million

Startup time
Total headcount
Annual output capacity
Market distribution
Product application

March 2015

December 2016

94 (Salary employee 22, Primary labor 72)
100,000 m322,000 m3(Industry2,000m3 +Building 20,000m3)
Asia Pacific, USA, Middle East and Europe
Industry and BuildingPittsburgh Corning (Yantai) Insulation Materials Co., Ltd✓✓✓✓✓✓✓✓✓

Product advantage

Constant insulating efficiency and lifelong
Non-combustible
High compressive strengthNon-absorbent
Corrosion/chemical resistant
Impermeable to water and vapor
Easy to work withVermin resistantLong term dimensional stability

Core technology

The FLAT manufacturing process of FOAMGLAS®
comprises 4 stages:✓ Produce Glass Frit from melter (Yantaiimport the Glass Frit from Europe plants)✓ Glass Frit grinding to powder after mixing
with foaming agents✓ Furnace foaming and annealing process✓ Cut and trim to product at FINISH process

The product could be tailor-made as
user’s requirement, with the purposeof helping customer saving time andcost during installation.

Major equipment

Ball mill，Furnace，Annealing Oven ，Main Saw，
Packing line

CNC，Fitting equipment

Major achievements
and recognitions

ISO45001, ISO14001, ISO9001 certification
ASTM C552 Grade 6,8,10,12 certification
ASTM 1639

2. Milestone on the Journey of Manufacturing Excellence2.1 Why We Do TPM
In 2012, OC Asia Pacific leadership team committed on TPM as one of the sustainable
development objective, there are several OC plants in this region already successfully achieved
TPM Award of Excellence and the Award of Excellence in Consistent which bring the great
product competitiveness and people capability for OC businessdeveloping in the market.
Based on the influence of Customers, Competitors, Company,Politics, Economy, Society and Technology on thedevelopment of our Company, and the plant annually SWOT
analysis results and OC company sustainability strategy, Yantai
plant decided to deploy the TPM methodologies to build thepreventive maintenance system to maintain the equipment in best condition and reduce the related
loss continuously

Pittsburgh Corning (Yantai) Insulation Materials Co., Ltd
2.2 Yantai Plant TPM Journey
Yantai Plant introduced TPM to the organization in Dec,2019, We are determined to maintain
optimal manufacturing condition and avoid potential deterioration. The main goal for Yantai Plant
is to restore the initial condition of our equipment and achieve zero breakdowns, zero accident
and zero defects. With the support from the internal and external consultancy, we follow JIPM
approach to implement TPM within the whole plant, started from our pilot area- Raw material
mixing area.
Raw material mixing area suffered high breakdown/ Minor Stop rate and serious carbon pollution
initially. Selecting that area as the TPM pilot area, we aim to accomplish zero breakdown /minor
stop and make it dust free in this area. Include 3 years consistency on TPM activities, we alreadyachieved 1 million workhours recordable injury free, 74% breakdown and 10% CONQ reduction,
which convince all the employees believe that TPM is the way we need to insist; After 1year TPM
running in pilot area, we extended TPM activity to the entire grinding and furnace area, then rollout to entire plant. Up to now, every employee actively engages in TPM activities; all equipment
list in critical A&B column are restored to basic condition.
When we are moving on our TPM journey, we expanded our efforts according the plan and focus
on these six Pillars execution - FI, AM, PM, TD, QM, and EHS.
In November of 2022, OC Global TPM director and his team assessed our TPM progress, herecommended us to pursue the official JIPM Award of Excellence assessment in year of 2023.
Meanwhile, plant not only considers it should be a good opportunity in our TPM journey but also
from site leaders to field employee are all willing to take this challenge.
Here is the plant TPM master plan since Y2019:
2019

2020

2021

2022

2023

Kick off

Pilot Stage

Expansion

Roll out

SustainApplication
Implementation
Preparation
Main Activities

TPM internal assessment
10%

TPM internal assessment
15%
Brother Factory visiting andlearning

TPM Steering TeamTPM Plant Master PlanTPM Introductory
Training
TPM Policy

Pillar Organization andResponsibility
Pillar Master Plan
Loss Tree Analysis
5S Activities

TPM internal assessment
20%

TPM internal assessment
Score 30%

TPM internal assessment
Score 43%

3% OEE improvemet

2% Unit Cost reduction

TPM Excellence Award
Challenge

Kaizen cases accelerated
to eliminate Loss

Skill Gap closure 80%
Skill Gap closure 90%
Zero Defect Project

T&D 6 Skills Training
Zero Recordable incident
Zero Loss Project
Zero Break down Project

T&D Training Centerstartup

2nd Floor of Grinding,
TPM Pilot Area

Pilot Area AM Step2

Pilot Area AM Step4
60% Equipment start
AM activities

60% Equipment AM
Step4>80% Equipment AMStep4

Pittsburgh Corning (Yantai) Insulation Materials Co., Ltd

3. Benefits Achieved
3.1 Tangible Results
When kick off the TPM, we seen the 2019 performance data on SQDCPM as a baseline start.
After 3 years these consecutive results proved adoption of TPM is the right choice. TPM activities
overall elevated our plant performance through improving equipment reliability and enhancing
employee operations skill.
As in workshop, through the deployment of AM step 1 to step 4 activities, the work environment
from pilot area to entire plant are all changed, easier for cleaning, inspection and lubrication,
Preventive Maintenance system works more effectively, tag and de-tag activities are becoming adaily common process on the shop floor, the equipment operates more stably. With the loss tree
analysis and the application of structured FI problem solving approach, we achieved zerobreakdown case over 1 year in pilot area.
3.2 Intangible Results
Employee ownership and engagement were turned around. The operators experienced a total
mindset change. Now they truly own their machines but not only operate them. People are eager
to know the equipment function and raise ideas to improve processes and equipment reliability. A
win-win situation was expected buildup while employees enhanced their skills with better work
results and the plant also benefited from people growth

4. Key of our Manufacturing Excellence
TPM is our way to manage operations to achieve ‘zero accidents, zero breakdowns and zero
losses’. Our commitment and engagement to practice TPM for achieving Operational Excellence
is unwavering. We firmly believe that the adoption of TPM methodology and tools will enable us
to become a world-class manufacturing facility eventually.
Since the introduction of TPM to the plant in 2019, we accomplished our vision, mission andobjectives according to OC global strategy, defined KPI/KAI and masterplan of 6 pillars. Throughtotal participation, governance meeting and management activities achieved the mindset change
and strong engagement of our people. Most importantly, as the deployment of these pillars acrossthe plant, enhanced ownership and engagement were achieved.
Clear vision and objectives of pillars and small groups are essential to achieve a good result. Tag
and De-tag activity are very useful tools for us, we set up a systematic activity flow to achieve
daily change. Leadership and ownership are the most critical factor. In Yantai Plant, allemployees are actively engaging in TPM activities. Regular training center upgrading according
to the equipment failure analysis result is important for operator skill improvement continuously.

Pittsburgh Corning (Yantai) Insulation Materials Co., Ltd
We have been proactively and deeply analyzing the root causes of all losses on safety, quality andstriving for continuous improvement on processes and equipment. We have also been spending
great efforts on engaging our people and elevating their skill sets. We firmly believe that we willachieve Zero breakdown, Zero accident and Zero defect across whole organization and reach
operational excellence.

5. Achievement Record
Company & plant name

Pittsburgh Corning (Yantai) Insulation Materials Co., Ltd

TPM Slogan/Objectives NO TPM, NO GROWTH; KNOW TPM, KNOW GROWTH

Category
SIndex(Calculation Formula)

Unit

Kick off/Actual
TPM
Target JIPM
StatusStarted2023
Use2022
2019

P

Number of work-related accidents Cases/year
requiring days off work
Number of work-related accidents Cases/year
not requiring days off work
OEE (or Overall Plant Efficiency) %P

Availability%

100.0099.17

100.00P

Performance Rate%

87.40

89.66

90.91

P

Quality Products Rate (NE%)

%

69.24

71.83

73.30

P

Number of breakdowns

Breakdowns/year

210

4360

PMTBFHour

423323300

PMTTRHour

0.51

0.52

0.40

Q

Number of customer complaints

Number/year

100Q

In-line defect rate (scrap)

%

7.43

6.17

5.00

C

Cost index

Cost/cum

1554

1468

1417

DProduction Lead time

Hour

86.42

62.42

44.77

DDelivery performance

%

9999

100

S

Frequency rate

Number of occupational

0000347360

S000000

60.52

63.87

66.64

accidents with leave for 1000 000 worked hours

M

Number of Employee Suggestions Number/yearPittsburgh Corning (Yantai) Insulation Materials Co., Ltd<Specify achievements not expressible in numerical terms>1. Do you have a program where all employees can participate in TPM?
Yes. All employees participate daily in the TPM program, through by activities,
such as:✓ Daily AM activities (Cleaning, creating OPL, tagging, de-tagging
autonomous and general inspection)✓ Eliminating Losses by participating in Kaizen activities✓ Training others on shop floor (Some people have been trained and certified
as TPM internal trainer)✓ In our daily performance meetings (Huddle)✓ TPM small group activity weekly
2. Do you have a program allowing employees to be recognized theirachievements?

Other✓ We have a monthly and/or yearly bonus structure that allows us torecognize the achievements of all employees. This bonus has defined
criteria for Safety, Quality, Delivery, Cost and Talent KPIs.
✓ Also, we have monthly Excellent OPL selection and Quarterly TPM starrecommending bonus structure.
✓ TPM skills as a job capacity requirement listed in job position promotionand employee recruitment.
3. Are top management involved in the audit/verification of completion ofTPM pillar steps?
✓✓✓
4.

Yes, we have a three-level audit system and assessment standards
Small Group Self-Assessment
Pillar Team Assessment
Plant TPM steering committee Assessment.
Are all pillar activity boards displayed and reviewed by topmanagement?
Yantai plant activity boards are displayed on shop floor, maintained by TPM
small group daily, reviewed by pillar team member weekly and audited by
TPM steering committee team monthly base.

2023 TPM Award -Achievement SheetCompanyOwens Corning

Plant name

Pittsburgh Corning (Yantai) Insulation Materials Co., Ltd

TPM Slogan/Objectives

No TPM No Growth, Know TPM Know Growth.

Year when TPM activity
startedYear of benchmarking

Category

2019-12
2019Index(Calculation Formula)

Kick off/TPM
UnitStarted (or lasttime awarded)

Actual Status2022

Number of work-related
SCases/ year

00

accidents not requiring days off Cases/ year

00Parts/Operator hours

0.11

0.17%

86.5

93.9

accidents requiring days offwork
Number of work-related

SworkPPP

Productivity for main products
OEE(or Overall Plant Efficiency)
Availability%

98.7

99.5

P

Performance Rate%

94.3

98.5

P

Quality Products Rate%

92.995.8

P

Number of breakdowns

Breakdowns/ year

21041PMTBFHour42321

PMTTR

Hour0.510.26

Q

Number of customer complaints Number/year

10Q

In-line defect rate, scrap%NANA%

5.50%

5.22%

1,611.3

1,471.4

Q

In-line defect rate, scrap andrework

C

Cost index

RMB/M3

DProduction Lead timeDays

43

DDelivery performance%

9599000372

Accidents perS

Safety index

1,000,000 operator
hours

M

Number of Employee
Suggestions

Number/year