Maintenance Reliability_2015

Creating a Company that would Put Yours

out of Business!

A Look into the future for Manufacturing

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

SO WHY DOESN’T ALL MANUFACTURERS HAVE

WORLD CLASS MAINTENANCE PROGRAMS?

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

SO WHY DON’T YOU HAVE A WORLD CLASS MAINTENANCE PROGRAMS?

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)

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?

From my Vantage Point, You Don’t have

time not to Be Proactive!

Is faster Better?

Is “More” Better

Just another Quick Fix

Myth: Faster is better! So how fast is fast enough?

From my Vantage Point,

Slower is Faster!

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)

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

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

Clarity

Accountability

Alignment - Balance

Visual Maintenance is all About

What Does Your maintenance Program Look Like?

RM

RM

RM

RM

RM

Reactive Maintenance

SM

SM

SM

Scheduled Maintenance

PM

PM

Predictive Maintenance

BALANCE

Machine Optimization

Optimized Performance for a Category of Machines

A complete Plant Overhaul

Targeted Custom Solutions

Visual Maintenance SolutionsDelivering IMPROVED Performance on the Floor

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.

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%.

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!

Visual Maintenance is Results you can

SEE!

Proper Maintenance is all about Balance

Scheduled Maintenance Over Time

Dashboard Demo Screen Shots

Proactive Maintenance Over Time

Reactive Maintenance Over Time

In Closing we would Like to Challenge each of you to…

THINK

From a Different Viewing Point!

Because…

Today You are IN Business

Tomorrow You could Be OUT of Business

Questions?Sources: www.reliabilityweb.com