| Client: Major Automotive Parts Manufacturer |
Client Success Stories
Charles Brooks Associates, Inc
| BACKGROUND: High temperature, complex production environment that required continuous maintenance to produce. Lack of communication between the maintenance department and the production departments. Preventative Maintenance routines were found to be substandard due to the lack of detailed procedures; causing production to question giving up their equipment for maintenance time. The facility had a high level of repeated breakdowns. SURVEY: Charles Brooks Associates conducted a brief analysis which revealed: The current Computer Maintenance Management System (CMMS), PMC2000, was completely under utilized; Maintenance activities were almost entirely reactive, repairs were mostly “band-aids” and didn’t repair the root problem; No records of or plans for management, supervisory, operator, or maintenance training; Lack of any measurements to actively track the success of the maintenance department in maintaining the facility; The PM work orders reviewed were weak in terms of description, settings, and tolerances. ACTIONS: Cleaned up the PMC2000 CMMS that is being used by the maintenance department. Eliminated all obsolete work orders and personnel information and then implemented planning and scheduling system using the capacity planning module in the system. Developed work flow diagrams that detail the entire planned maintenance process that we are implementing at the facility. Created numerous custom reports that extracted necessary information from PMC2000, so that we could measure our success as we moved to a more proactive maintenance organization. Analyzed existing PM tasks and developed new PM procedures with specific tolerances and specifications for the critical equipment in the facility. Developed maintenance skills and equipment specific skills matrices to assess the overall ability of the maintenance department to maintain the facility. Used this information to target required training. RESULTS: The facility has a fully functioning CMMS that can be used to plan and schedule maintenance activities. The entire maintenance process has been documented using work flow diagrams. These diagrams can be used for training maintenance and production personnel. Updated PM procedures with specific tolerances for the entire production process. Key measurements are now in place to track the progress of the maintenance group. Ensured that the Maintenance Excellence process was self-sufficient and would continue on after Charles Brooks Associates, Inc. was no longer on-site. |
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