Transcript Reactive to Proactive Maintenance through LEAN

Reactive
to
Proactive
Maintenance
through
LEAN
What is
Reactive,
Proactive and
Lean?
Where do we find these wastes in maintenance processes???
3P: Production Prep Process
What is meant by
“TOTAL”
Productive
Maintenance
Parent, Baby and Doctor!!!
TPM
A set of activities for restoring equipment to its
optimal condition and changing the work
environment to maintain those conditions
through daily maintenance activities.
To identify productivity losses and involve all
members of the company in loss elimination
programs.
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What is TPM??
TPM is a Lean tool to optimize the effectiveness of
manufacturing equipment and tooling.
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4.
5.
Starts with 5S / Visual Factory
Builds a comprehensive Downtime Database by cause,
frequency, and duration
Predicts and prevents downtime by PM system
Expands role of Operator as first point of early warning and
prevention
Develops Professional Maintenance skills
What is
5S
What is FOCUSSED
IMPROVEMENT
Visual Controls…
Planned Maintenance!
What is wrong with
CORRECTIVE
MAINTENANCE?
What do we do in
planned
maintenance??
Where does it touch
boundaries with
PREVENTIVE
MAINTENANCE
Downtime Database
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Categorize by equipment, type of breakdown etc.
Segmented bar graph for lost time
Subcategories for Equip (e.g.)
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Subcategories for Tooling (e.g.)
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Hydraulic / pneumatic
Mechanical / lubrication
Electrical / controls
Shot-end components
Slides
Cores
Inserts
Ejector pins
Subcategories for Other (e.g.)
– Operator error
– Materials
Minimum
Downtime
Tracking
Downtime
by Cause 3500 ton Bay
(avg min/shift per Machine)
Other 120
Tools
100
80
O
Minutes 60
T
40
E
20
Equip
0
1Q02 2Q02
Jun
Jul
Aug
Sep
Oct
Nov
Example from Cyanide Plant – Calculation of lost time.
Example of HLP Machines
Dec
Predictive Maintenance Tools
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Actual Rate/hr vs. Design or target Rate/hr (or historical normal output)
Database
– Maintenance history
– Statistical probability (frequency & duration)
– Downtime between failure
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Physical prediction of impending failure
– NDT
– Sound (bearing)
– Temperature (cooling water)
– Flash (core pins)
– Shot monitoring system
– SPC on part geometry
– Hydraulic pressure (ejector pins)
– Spindle loads (amps)
– Fluids / Lubrication analysis (milipore)
– Vibration Signature Analysis
Breakdowns & Defects Can Be Divided Into 2 Loss Categories
1. Sporadic Loss:
Defects suddenly occur, or a piece of equipment
suddenly stops. The root cause is usually easy to
locate.
2. Chronic Loss:
This type of loss does not occur suddenly. There is
usually more than one type of cause to the loss,
which makes the root cause difficult to locate.
How would you deal with either of these types???
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Why Should A High Priority
Be Placed On Slight Defects?
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Stop the snowball effect of accumulating defects.
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To get to the root cause.
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Slight defects will develop into critical defects.
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Forced deterioration will shorten the life span of the equipment.
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2 Types Of Equipment Deterioration
Natural Deterioration:
Physical wear that occurs even though
the equipment is used and maintained
properly.
Forced Deterioration:
Natural deterioration that is increased
from negligence on our part, such as
lack of oiling, checking, repairing, etc.
How would you deal with either of these types???
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This leads us to the concept of
EARLY MANAGEMENT
Rules For Zero Failure
ÜDiscover latent defects to prevent failures
“Failure” is only
the tip of the
iceberg
FAILURE
LATENT DEFECTS
Dust, soiling, adhesion of raw materials.
Abrasion, backlash, looseness, leaks
Corrosion, deformation, flaws, cracks
Temperature, vibration, sound, and other errors
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Levels Of Skills
Level 0 Do Not Know
Lack Of Knowledge
Level 1 Know The Theory
Lack Of Training
Level 2 Can Do To Some Degree
Lack Of Training
Level 3 Can Do With Confidence
Learned By Doing
Level 4 Can Teach To Others
Knows Extremely Well
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Ability Needed From Operators
Ü
Ability To Find & Improve Equipment
Problems
Ü
Understanding Of Equipment Functions
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Understand The Relation Between
Equipment & Quality
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Can Replace Consumable Parts
Ü
Good Team Member
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Ability Needed From
Maintenance Group
Ü
Can Teach The Proper Operation & Daily
Maintenance of Equipment
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Judge If Equipment Is Operating Normally
Or Abnormally
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Respond To An Abnormal Condition,
Select, & Implement A Timely Repair
Ü
Technical Skills To Diagnose Equipment &
Prevent Breakdowns
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Your Role as MAINTENANCE
TEAM MEMBERS
?
?
Analyse how equipment contributes
to quality defects and maintain
them out
Example of HLP Machine
CONCLUSION
through discussion
How do you think today’s discussion
can lead us from Reactive to
Proactive Maintenance???