Maintenance Excellence for Operations

Your Gateway to Operational Excellence
© PSL 2010 All Rights Reserved
Maintenance Excellence for Operations

Group Activity - Why Equipment Fails
Poor design?
Running the wrong products?
Lack of maintenance?
Lack of care?
What are your key issues, write your
answers below
Time allowed – 15 minutes
Use the sheet below to collate
your answers
This document is a partial preview. Full document download can be found on Flevy:
http://flevy.com/browse/document/maintenance-excellence-for-operations-presentation-1040

The Solution – Proactive Maintenance
Prioritize your opportunities for
improvement
Provide a framework for
improvement
Equipment Stabilization
Team Knowledge
Equipment ImprovementThis document is a partial preview. Full document download can be found on Flevy:

Prioritization – Where to Start
Quality
Losses
Opportunity
Improve
Equipment
Performance
Availability
Losses
Performance
Losses
Breakdo
wns
Changeo
vers
Speed
Loss
Minor
Stops
Yield
Loss
Defects,
Rework
your answers

World Class Benchmarks – OEE
OEE = Availability x Performance x Quality
Process Benchmark Australasia
Batch Process > 85% 16-60%
Continuous Batch Process >95% 65-90%
Continuous Process >98% >98%
OEE Factor Benchmark
Availability 90.0%
Performance 95.0%
Quality 99.9%
Overall OEE 85.0%
Factor based:
Process based:
your answers

Availability Losses – Setup/Adjustment
Time lost through
1. Changeovers
2. Subsequent adjustments

Performance Losses – Minor Stoppage
Not a breakdown but a
temporary problem
Stops the machine or causes
idle running.
Simple counter measures can
improve this loss and restore
normal condition

Quality Losses –Rejects, Rework or Scrap
A loss of defective materials and
products disposed of in production
processes
Man-Hour loss for rework due to
defective parts

Observe the making of a milkshake.
What is the availability, performance
and quality rates for this process.
Time allocated = 20 minutes
Group Activity
your answers

Initial Clean and Inspect
“Cleaning with Meaning”
identifies problems and root
causes
It allows team to establish
o Identify lubrication issues
o Identify any loose parts or
vibration issues
o Identify any sources of
contamination
Sources of problems can be
eliminated once they are
identified

Maintenance Strategies - TPM
Total Productive Maintenance (TPM) helps
you achieve –
o Higher Production Efficiency
o Uninterrupted Operations
o Quick, Proactive Maintenance Response.

RCM Teams
o Analyses the process
o Pinpoints faults or areas of opportunity
o Fixes it to make it more robust.

Project Evidence – Part 1
Lead team in monitoring process and equipment
1.1 Demonstrate to team how to observe the
process/equipment continuously and critically using
appropriate senses (sight, hearing etc) to identify
any potential or actual problems
1. 2 Identify to team data indicators that must be
monitored and recorded
1.3 Ensure team monitors identified data indicators
frequently and critically
1.4 Ensure symptoms of operations outside the desired
range of conditions and performance are
recognised
1.5 Analyse cause of equipment non standard
performance within scope of knowledge and skill
1.6 Ensure team members take timely and appropriate
action to solve problem or to refer problem to
appropriate manager or specialist

Project Evidence – Part 4
Facilitate team contribution to proactive maintenance
4.1 Monitor team's contribution to proactive
maintenance
4. 2 Arrange for competency development of
team members as required
4.3 Facilitate ongoing examination by the
team of process reliability and overall
equipment efficiency (OEE)
4.4 Arrange for follow through and
implementation of team originated
improvements

Maintenance Excellence for Operators
Session Two – Making the Difference

Group Activity - Using our senses
Sight Sound Smell
In small groups pick two of the
following senses and decide
where you could use them to
identify equipment related
problems.
Sight, Sound, Smell, Touch,
Taste
Time allowed – 20 minutes
your answers

Lubrication Frequency
How often and how much will depend
on your equipment usage.
Too little will give you problems as
equipment will deteriorate faster.
Too much and it may overheat and
spillage can create a contamination
issue.
Time or usage based?This document is a partial preview. Full document download can be found on Flevy:

Lubrication Standards and Training
Agree and set standards
Monitor and adjust as required
Develop checklists
Train staff in requirements

Introduce daily checks
Is the lubricant getting to the parts that
need lubricating?
Are quantities and temperatures within
specified limits?
Are there any leaks?
Is the lubrication discoloured, cloudy or
foaming?
Listen for unusual noises or vibration?
Are you having to use more than
specified?

Reducing Vibration
Many shock and vibration isolators
are available from your local
engineering supplier
You should seek engineering advice
on the right one/s for your application
Vibration Isolators &
Dampers

Visual Management - Alignment
Use alignment markings for
chains and belts
This will quickly identify any
tension problems and prompt a
replacement or re-adjustment
Consider also using perspex
covers with quick access
fittings. This will remove the
need to take covers off and on
during inspectionsThis document is a partial preview. Full document download can be found on Flevy:

Eliminating Contamination
To eliminate contamination
we must contain it at its
source
Contamination degrades
equipment and requires
resource to clean it up
Reduce and eliminate both
equipment problems and
housekeeping by containing
the problem at sourceThis document is a partial preview. Full document download can be found on Flevy:

Group Exercise
your answers
In small groups identify the
opportunities in your work
area to reduce the
equipment damage due to
contamination and also
reduce the cleaning cycles.
Develop an improvement
strategy for your work area
Time allowed – 20 minutesThis document is a partial preview. Full document download can be found on Flevy:

Visual Controls
Visual Controls make
checks quick and easy for
the operator
Red Zone =
Incorrect operating
pressure
Green Zone =
Correct operating
pressure

Visual Controls
Attach small fabric
streams to air outlets
identifies that they are
working correctly

Workplace Project Presentation
Plan and present a project on what you have learnt and what has been implemented
in your workplace. Be prepared to present this at the next session.
• Form groups of 2 or 3 people
• Can be practical or formal presentation
• OEE improvement projects
• How you involved your team
• Impact of equipment changes

Wrap Up
• Participants identify one key item that they
will remember from today’s session
• Good luck !
Keep it Clean, Green and Lean

1
Flevy (www.flevy.com) is the marketplace
for premium documents. These
documents can range from Business
Frameworks to Financial Models to
PowerPoint Templates.
Flevy was founded under the principle that
companies waste a lot of time and money
recreating the same foundational business
documents. Our vision is for Flevy to
become a comprehensive knowledge base
of business documents. All organizations,
from startups to large enterprises, can use
Flevy— whether it's to jumpstart projects, to
find reference or comparison materials, or
just to learn.
Contact Us
Please contact us with any questions you may have
about our company.
• General Inquiries
support@flevy.com
• Media/PR
press@flevy.com
• Billing
billing@flevy.com

Maintenance Excellence for Operations

Empfohlen

Empfohlen

Weitere ähnliche Inhalte

Mehr von Flevy.com Best Practices

Mehr von Flevy.com Best Practices (20)

Kürzlich hochgeladen

Kürzlich hochgeladen (20)

Maintenance Excellence for Operations