Daily Team Maintenance, Planned Maintenance, 5S · Maintenance Planned Maintenance Integrated Model Equipment Stability Decreased Minor Stops Decreased Breakdowns OEE Increases and

Daily Team Maintenance,

Planned Maintenance, 5S

A Successful Performance System Includes:

Milliken Performance System

Daily Team Maintenance

and Planned Maintenance

The 4 Phase Process

DTM and PM 4-Phase Approach

Is This Your Current Situation?

Minor stops

Breakdowns

OEE

YieldMorale

Safety

• A dirty work environment is

typical

• Machinery failures are

normal

• Accelerated deterioration

and abnormalities are

expected

• Operators “run” and

technicians “fix”

Conventional

Thinking

Evolution of Key Roles

0

50

% T

ime

Basic Operation

Daily Inspection

Improvement,

Small Repairs

Operator

100100

Maintenance

Breakdown Repairs0

50

% T

ime

Preventive

Maintenance

Corrective

Maintenance

Maintenance System

Management

Maintenance Techniques (FMEA, CBM)

Operation Breakdown Repairs

Care for Equipment Breakdown Elimination

Transfer Basic

Maintenance Skills

and Tasks

Integrated Model Approach

Daily Team

Maintenance

Planned

MaintenanceIntegrated Model

Equipment

StabilityDecreased

Minor Stops

Decreased

Breakdowns OEE

Increases

and Cost

Reductions

Are

Achievable

Lean

Manufacturing

DTM and PM 4-Phase Approach

Phase 1:

Reduce

Breakdowns

Phase 2:

Lengthen

Equipment Life

Phase 3:

Implement

Periodic

Maintenance

Phase 4:

Predict

Equipment Life

DTM

Steps 1-3

DTM

Step 4

DTM

Step 5

DTM

Steps 6-7

PM

Steps 1-2

PM

Step 3

PM

Step 4

PM

Steps 5-6

5S

Focused Improvement

Continuous Skills Development

Daily Team Maintenance

Who: Cross functional teams of

Operators, technicians, maintenance,

production leadership

How: 7-Step process implementation

Why: Targets losses due to minor

stops, breakdowns, changeover time

Where: Model Equipment first, then

all equipment plant wide

What: DTM Provides operators with the

knowledge and skills required to

proactively prevent breakdowns and off-

quality caused by accelerated

equipment deterioration and

abnormalities.

DTM Pillar

Team

Team Leader

M

M

M MM

M

Replication

Team 1

M

M

MM

M

Team

Lead

Replication

Team 2

M

M

MM

M

Team

Lead

8

8

7

10

6

5

5

6

7

7

0 2 4 6 8 10

CNPD

EEM

PC

QM

CSD

FI

5S

PM

DTM

SAFETY

Pillar Steps

Pillar Steps

7- Step Implementation Process

DTM Improved Our:

•eliminated dirt, contamination & deterioration

• reduced breakdowns & downtime

•defined standards for optimal equipment

conditions

•educated operators on the identification &

repair of abnormalities

• increased operator awareness and responsibility,

& equipment knowledge

• freed up technicians to troubleshoot and

redesign

• created an environment of pride, ownership,

and responsibility

•eliminated the barrier between operators and

technicians

Equipment

People

Culture

DTM and PM 4-Phase Approach

Phase 1:

Reduce

Breakdowns

Phase 2:

Lengthen

Equipment Life

Phase 3:

Implement

Periodic

Maintenance

Phase 4:

Predict

Equipment Life

DTM

Steps 1-3

DTM

Step 4

DTM

Step 5

DTM

Steps 6-7

PM

Steps 1-2

PM

Step 3

PM

Step 4

PM

Steps 5-6

5S

Focused Improvement

Continuous Skills Development

Planned Maintenance

PM Sub-Pillars

DTM SupportSpare Parts

Management

Lubrication

Management

Maintenance

Team Skills

Enhancement

Predictive

Maintenance

Preventive

Maintenance

Maintenance

Cost

Management

Zero Failure

Activities

• Zero breakdowns

• Improved reliability

• Improved maintenance

skills and capabilities

• Reduced maintenance

spend

PM Improved Our:Maintenance Process

•established a predictive and preventative maintenance system & schedule

•developed metrics around maintenance

•provided methods to analyze and understand cost

Equipment

•Provided tools to analyze, track, and document machine failures

•Eliminated root causes

• Implemented countermeasures to prevent recurrence

Associates•Provided education for technician (and operators) to raise

skills levels

•Assisted CSD pillar is DTM operator training

Roles: Operators vs Maintenance

• trouble-shoot major problems

• improve equipment by

correcting design weaknesses

• assist teams in machine

restoration and

countermeasures

• provide technical support to

operators

• educate operators to:

➢ clean

➢ tighten

➢ lubricate

➢ identify abnormalities

➢ identify deterioration

• “own” their machines

• maintain basic machine

conditions:

➢ cleaning, tightening, lubricating

• identify deterioration

• identify abnormalities before

breakdowns

• work with technicians to make

minor repairs

• participate in root cause

analysis

• develop skills/knowledge:

➢ machine function, minor repairs

➢ visual inspection, proper

operation

After

DTM/PM

• fix breakdowns and minor

stops when they occur

• “I run it, you fix it!”

• inability/knowledge to detect

and correct abnormal

conditions

Operators Technicians

Before

DTM/PM

5S

How is it different?

Ensures Associates have:

What they need

Where they need it

When they need it

… to sustainably

eliminate inefficiencies

5S is not just housekeeping!

Questions?

Jeff RosenlundDirector of Client Engagement

Performance Solutions by Milliken