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| LEAN MAINTENANCE A well-proven approach toward Total Productive Maintenance Lean Maintenance is a process which ensures a continuous improvement in the quality of maintenance work carried out on production equipment which leads in turn to higher efficiencies and a reduction in the cost of non-conformance. We have observed, over many years in diverse industries, that clear goals of achievement for mechanics are rarely established. It is equally rare that measurements are made of mechanics' performance. The seven forms of maintenance waste are not measured or understood. Furthermore, in most plants, there exists a wider variation in mechanics' understanding, skill and motivation than is generally realized. This results in variations in accuracy, and consequent losses in equipment performance. The situation is aggravated any time there is a shortage of skilled mechanics. This state of affairs can be remedied by the introduction of a Lean Maintenance program which will lead to not only improvements in the quality of repairs and higher machine performance, but also higher morale and job satisfaction among mechanics. Furthermore, the creation of standard machine conditions facilitates the faster training of new mechanics and operators. KEY FEATURES Defined Equipment Standards - In our Lean Maintenance program the emphasis is on a strong planned maintenance program in which the proper items are checked carefully and accurately at the proper intervals. Additionally, parts replacement and adjustments are made where necessary on a consistent and accurate basis. The definition and agreement of standard speeds, settings, tolerances, worn parts replacement criteria, etc. is developed with the full participation of the experienced mechanics and maintenance staff. These are referred to as Defined Equipment Standards. Critical Component Analysis - Experience usually shows that the majority of maintenance required by any given piece of equipment is caused by a relatively few critical sub-assemblies or components. Similarly, there will be a relatively few sub-assemblies having a critical effect on productivity, product quality, waste or off-quality and machine efficiency. A careful analysis will usually identify these critical sub-assemblies or components. Early attention is concentrated on developing the Defined Equipment Standards for these critical components. Proficiency Training - Where necessary, maintenance staff and mechanics are re-trained in the most effective and efficient methods of applying the Defined Equipment Standards. This raises the level of comprehension, commitment and skill, thereby reducing variations in performance. Upgrading of Equipment (Restoration) - Equipment that is far below standards is upgraded to the Defined Equipment Standards and carefully checked with the involvement of client staff. Operating Department Liaison - Production staff and operators are consulted in the analysis of critical components to ensure that operating practices are not counter-productive to the maintenance effort required to maintain Defined Equipment Standards. Production operators are retrained where necessary using client's instructors. Autonomous Maintenance - Operators and/or production technicians are trained to perform basic maintenance on their assigned equipment, to maintain equipment in proper working order to Defined Equipment Standards, and to develop the ability to detect deterioration and problems before breakdowns occur. Predictive Maintenance - Maintenance staffs are trained to monitor the condition of equipment during operation and to diagnose evidence of probably imminent failure through the introduction and adoption of predictive maintenance techniques. Maintenance Planning - A cooperative program involving both Production and Maintenance personnel is developed to ensure that full advantage can be taken of equipment outages to complete planned maintenance. Scheduling Analysis - The optimum maintenance intervals are determined taking into account all relevant production, quality and machine factors. Development of a Performance-Related Evaluation System - An effective method is required of assuring that maintenance to Defined Equipment Standards has been done properly. This requires an accurate but rapid evaluation system. In this way, a portion of equipment can be graded regularly, giving a regular measure of the effectiveness of each mechanic's performance. This has a strong motivational effect and results in a higher standard of maintenance. A considerable reduction in the number of malfunctions enables mechanics to spend appropriate time on planned maintenance work. On multi-position equipment, a randomly selected number of positions can be checked to arrive at a grading for the overall machine. Control - A rapid, documented feedback of both machine and mechanic performance is designed. This not only enables management to monitor and control conditions, but also serves to motivate mechanics and to build pride in the performance of their jobs. Participatory Approach - Most plants have had experience with various maintenance improvement programs, and many of them have fallen by the wayside. Many mechanics - and, perhaps, not a few managers - feel that planned maintenance programs are fine in theory but do not stand the test of time in practice. To minimize any doubts about the practicality of the program and to assure success, a key factor in introducing Lean Maintenance is the complete involvement of mechanics and their supervisors in the development of the process. BENEFITS Lean Maintenance can contribute significantly to higher productivity, increased profits, improved maintenance management and other important benefits: Improved Equipment Output: Typically as much as 15-25% through a reduction in waste such as: controllable downtime; reduced set-up and start-up losses; and increased mean time between failures. Improved Product Availability and Yield: Typically by 20-50%; sometimes more through a reduction in process defects, off-quality and scrap. Increased Labor Productivity: By as much as 15-20% through improved mechanic utilization, reduced breakdowns, and improved equipment availability and reliability. Reduced Replacement Parts Cost: Typically by 15-20% through the improved definition of parts replacement criteria and a clearer understanding by mechanics of such criteria. Reduced Energy Costs: From morg srficient machinery. Faster Training of Mechanics: Through definition of required standards, measurement and control of mechanic performance and creation of standard conditions. Simplified Operator Training: Machinery consistently set to Defined Equipment Standards is easier to operate. Lower Labor Turnover and Improved Morale: Improved skill, confidence and success lead to improved morale and lower labor turnover. OUR APPROACH Following a discussion with one of our senior consultants, the first step is a short survey to determine the scope for our work, the benefits that may be expected, the costs involved and the resources the client should plan on making available to work with us. When invited to work with a company, we do not install "package" programs; neither do we merely make recommendations. Following proven principles and techniques, we assist clients to develop a continuous improvement process suited to their needs and personnel, with full participation of the staff concerned. We then work with them to achieve the expected results. A major aspect of our approach is to give thorough training to members of the client's staff so that they may continue the process successfully after we leave. |
Services
Charles Brooks Associates, Inc
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Performance Technology