Maintenance Reliability_2015
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Transcript of Maintenance Reliability_2015
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Creating a Company that would Put Yours
out of Business!
A Look into the future for Manufacturing
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If you are not a World Class Maintenance Organization…
Being World Class Doesn’t cost you more Money! It actually cost you less!
You won’t need to be - You’ll soon be Out of Business
Truths About U.S. Manufacturing!
At this time there is an estimated loss of $750 Billion due to breakdown maintenance (reactive) or generally poor, incorrect or excessive practices. SMRP Solutions June 2010
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SO WHY DOESN’T ALL MANUFACTURERS HAVE
WORLD CLASS MAINTENANCE PROGRAMS?
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The future holds great promise for knowledge workers in the field of maintenance and reliability. As the shortage of both high level and lower level skills becomes more pronounced, the competition to hire or contract with these knowledge workers will intensify. Companies that use cost to drive maintenance decisions rather than best practices will lose knowledge workers and see costs skyrocket. Companies that attract knowledge workers and implement best practices will see increased profits through higher availability and increased output, lower scrap rates, higher quality product, and finally lower maintenance labor and material cost.
The knowledge Gap
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SO WHY DON’T YOU HAVE A WORLD CLASS MAINTENANCE PROGRAMS?
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Vision
Value
Control
Feedback
Reactions to what gets your attention!
Execution Results
Management Leadership Initiatives
Corporate Resources
Third Party Resources
Command and Control Feedback Loop (Fire Fighting)
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On Delivery! On Maintenance! On Quality!
Impact On Profits! Competitiveness!
Myth: Don’t have time to be proactive. But, what is the cost of being reactive?
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From my Vantage Point, You Don’t have
time not to Be Proactive!
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Is faster Better?
Is “More” Better
Just another Quick Fix
Myth: Faster is better! So how fast is fast enough?
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From my Vantage Point,
Slower is Faster!
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Yesterday’s Value won’t make tomorrow's sales! We need a different context to win!
With a Vision Viewing Point You:◦ See problem from a larger perspective
◦ Focus on the little things that make the big difference – Leverage Points
◦ Activities are accomplished with a goal centric point of view: Delivering: VALUE, VALUE, VALUE...
Looking from a Different Viewing Point (Step 2 of Cultural Change)
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Vision
Value
Strategy
Tactical Initiation
Corporate Results
Control
Feedback
On-Course Correction
Execution Metrics
Management Leadership Initiatives
Corporate Resources
Third Party Resources
Corporate and CommunityDashboard
Command and Control Feedback Loop
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Vision
Value
Goals
Measures & Commits
Metric Reviews
Control
Feedback
On-Course Correction
Execution Metrics
Management Leadership Initiatives
Corporate Resources
Third Party Resources
Corporate and CommunityDashboard
Command and Control Feedback Loop
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Clarity
Accountability
Alignment - Balance
Visual Maintenance is all About
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What Does Your maintenance Program Look Like?
RM
RM
RM
RM
RM
Reactive Maintenance
SM
SM
SM
Scheduled Maintenance
PM
PM
Predictive Maintenance
BALANCE
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Machine Optimization
Optimized Performance for a Category of Machines
A complete Plant Overhaul
Targeted Custom Solutions
Visual Maintenance SolutionsDelivering IMPROVED Performance on the Floor
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Single Solution for One Machine - Bush Press
Mfg. Capacity 1500 parts per shiftCurrent Capacity 400 parts per shiftAvg. DT 2 hr./weekMfg. EOL 24 weeksActual 3 daysCritical Part 2 sets on hand
Current 8 sets
Cost-of Care $8,372.12 6mo. 2 sets of grippersThreshold Mgmt 45% below threshold
Gripper CostsProblem Alignment Brass $1,965.29
Solution
Re-Align the robot pick-up arm to the nest Steel $2,534.12
The reliability of the grippers are at 98% reliability after the first hour of operation. Given there were two different sets that failed at 48 hours and 52 respectively. The manufacturer informed us that the
grippers (Brass) would last 24 weeks or the reliability was 576 hours(expect to fail). Instead given our specified cycle time of 50 parts per hour, the MTBF(MTTF) was 50 hours, ironically.
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Single Solution for One Machine - Bush Press Solution
Mfg. Capacity 1500 parts per shiftCurrent Capacity 1000 parts per shift SavingsAvg. DT 0.25 hr./week $7160Mfg. EOL 24 weeksActual 6 weeksCritical Part 2 sets on hand
Current 8 sets
Cost-of Care $11.75 1 week Check for alignment and worn grippersThreshold Management 100% at threshold
Gripper CostsProblem Alignment Brass $1,965.29
Solution
Re-Align the robot pick-up arm to the
nestSteel $2,534.12
The reliability of the grippers are at 98% reliability after the first hour of operation. Given there were two different sets (Brass and Steele) that failed at 48 hours and 52 respectively. The manufacturer
informed us that the grippers (Brass) would last 24 weeks or the reliability was 576 hours(expect to fail). Instead given our specified cycle time of 50 parts per hour, the MTBF(MTTF) was 50 hours, ironically. After solution the grippers reliability factor was at 144hours, still below manufactures
reliability factor, after training the operator the reliability improved by 20%.
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On-The-Floor Maintenance Solutions
Goal Centric Driven Solutions
Custom Dashboards to fit your specific Requirements
Can Guide your Reliability Journey
What You Can Do - SummaryHelp your Company Drive DOWN Costs!
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Visual Maintenance is Results you can
SEE!
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Proper Maintenance is all about Balance
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Scheduled Maintenance Over Time
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Dashboard Demo Screen Shots
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Proactive Maintenance Over Time
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Reactive Maintenance Over Time
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In Closing we would Like to Challenge each of you to…
THINK
From a Different Viewing Point!
Because…
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Today You are IN Business
Tomorrow You could Be OUT of Business
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Questions?Sources: www.reliabilityweb.com