productive maintenance
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Productive Maintenance. Chapter 15. Productive Maintenance. Vision: Total life cycle equipment management Seeks to measure and improve overall equipment effectiveness. Productive Maintenance. Benefits Reduce costs Reduced inventories Reduce lead-time Reduce injuries - PowerPoint PPT PresentationTRANSCRIPT
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
Productive MaintenanceChapter 15
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
Productive Maintenance
• Vision: Total life cycle equipment management– Seeks to measure and improve overall
equipment effectiveness
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
Productive Maintenance
• Benefits– Reduce costs– Reduced inventories– Reduce lead-time– Reduce injuries– Reduce breakdowns (jams, standbys,
speed losses, startup losses, quality, etc…)
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
Productive Maintenance
• Benefits– Improved customer satisfaction– Improved productivity– Improved work environment– Improved quality– Improved change-over times
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
Productive Maintenance
• Benefits– Eliminate Waste
• Wasted Time• Wasted Resources
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
Productive Maintenance
• Where do production losses come from?
• Quality/non conformance issues• Raw materials shortages• Machines or equipment availability• Cycle time losses
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
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Productive Maintenance
• Productive Maintenance seeks to improve Overall Equipment Effectiveness (OEE)
OEE = Availability x efficiency x quality
– OEE is typically 50-60%, can climb to 80%
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
How will we accomplish
this?
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
Productive Maintenance
• There are four components to a productive maintenance program:– Elimination of equipment losses– Preventive maintenance– Predictive or planned maintenance– Autonomous maintenance
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
• Elimination of Equipment Losses: Prevent Downtime – Eliminate Breakdowns, the loss or reduction
of a specified function, which cause production losses, spoilage, lost time.
– Avoid Stops, Jams and Standbys that occur randomly and cause production lost time.
Productive Maintenance
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
Productive Maintenance
• Elimination of Equipment Losses: Prevent Downtime – Eliminate losses by
• Root Cause Analysis– Search out and correct all the slight defects in parts and
jigs involved in transfer of work
• Autonomous Maintenance – Proper maintenance over time is a good defense.
• Training to Create a Better Understanding of the Equipment
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
Productive Maintenance
• Elimination of Equipment Losses: Prevent speed loss– Design speeds vs. actual operation speed
• Changes to part/equipment may make it impossible to run at design speed
• Need to determine optimal running speeds during production
• Correct insufficient debugging, defective mechanisms, design weakness, insufficient equipment, increase precision
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
Productive Maintenance• Elimination of Equipment Losses: Reduce
Quality Defects– Find root causes and eliminate them in the design
of products, processes and machines.– Five Improvement Tools
• a) Pareto• b) Problem analysis• c)Ask why 5 times• d) Cause and Effect• e) PM Analysis
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
Productive Maintenance• Measure progress toward elimination of
equipment losses by:– Measuring the number of occurrences of
breakdowns, jams, and standbys– Measuring the duration of breakdowns, jams, and
standbys– Measuring spoilage rates– Measuring production rates – Measuring mean-time-between-failures– Utilizing run charts to track performance
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
Productive Maintenance
Preventive Maintenance– Preventive maintenance maintains the
equipment in good condition so that unexpected downtime does not occur.
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
Productive Maintenance
Preventive Maintenance– Periodic inspection of equipment to detect
conditions that might cause breakdowns and then follow-up action to reverse such conditions
– Scheduled maintenance – Start with high priority equipment
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
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Productive Maintenance
Preventive Maintenance1) Perform Long term Maintenance
• Plan• Schedule• Execute
2) Create Standards• Establish • Adhere to• Review periodically
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
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Productive Maintenance
Preventive Maintenance3)Create Plans
• Must plan for scheduled maintenance– What interval?
» Annual?» monthly?
– How will down-time be scheduled? – How much time to repair?
» major overhaul?– Have parts/materials been procured?– Has outside labor been scheduled?– Will budget cover the cost?
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
Productive MaintenancePreventive Maintenance
4)Maintain Records• Documentation of machine performance• Provides history
– helps with planning maintenance
• These records are used to assess equipment conditions, establish priorities, deploy resources
• Daily or periodic inspections provide records• Priorities based on production importance, quality
level, maintenance history, safety
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
Productive Maintenance
Preventive Maintenance4) Maintain Records
• What records are needed?• Why needed?• How used?
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
Productive Maintenance
Preventive Maintenance4) Maintain Records
• Simplify and Standardize Current Record-Keeping Procedures
– Routine inspection records– Lubricant replenishment/replacement records– Periodic inspection records– Repair and service reports– Maintainability improvement records
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
Productive Maintenance
Preventive Maintenance4) Maintain Records
• Simplify and Standardize Current Record-Keeping Procedures
– MTBF analysis– Equipment Logs– Maintenance Cost Records– Breakdown analysis records– Downtime occurrences and time
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
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Productive Maintenance
Preventive Maintenance 5) Spare parts control
• Necessary spare parts available when needed without having it sit around and go bad
• Analyze need, priority, storage method, restocking method, cost of stock
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
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Productive Maintenance
Preventive Maintenance6) Maintenance Costs
• Often over-budget– lack of planning– fire fighting verses prevention – not knowing real costs of waste
• Improve this by:– Building awareness– Monitoring expenditures closely– Responding to deviations quickly
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
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Productive Maintenance
Preventive Maintenance6) Maintenance Costs
• Reduce Costs by– 1) Forming Preventive Maintenance Teams– 2) Eliminating Equipment Losses– 3) Reviewing periodic maintenance intervals– 4) Switching from outside contracting to in-house
fabrication– 5) Reducing permanently stocked spare parts– 6) Using idle equipment effectively– 7) Reducing energy and resource use
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
Productive Maintenance
Preventive Maintenance7) Lubrication Control
• Proper lubrication – oils, cutting oils, greases, solid lubricants
• No leakage• No contaminants• Controlling the deterioration/contamination of lubricants
– daily inspection» Levels» Time» Rate of usage
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
Productive Maintenance
Predictive Maintenance– Predictive maintenance schedules routine
maintenance so that everyone knows and can plan for a machine or a piece of equipment being unavailable.
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
Productive Maintenance
Predictive Maintenance– Measuring, recognizing and using signals
from process to diagnose the condition of the equipment and determine when maintenance will be required
– Cost of monitoring should be less than cost of repair or production losses
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
Productive Maintenance
Predictive Maintenance Maintenance Prevention
– Design and acquisition of equipment that will be easy to maintain and operate
• Comes from equipment history – MTBF, time to overhaul
• Experience• Safety Records
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
Productive Maintenance
Predictive MaintenanceMaintenance Skill Training– Maintenance
• Workers with strong maintenance and equipment related skills
• An understanding of equipment• Develop expertise and skills
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
Productive Maintenance
Autonomous Maintenance– Performed by equipment operators
• Daily cleaning, inspecting, lubricating, bolt tightening; prevents equipment deterioration.
• 15 min/day• Transfers ownership to person running
machine
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
Productive MaintenanceAutonomous Maintenance Steps:
1) Thoroughly clean all equipment • may take place during plant shutdown
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
Productive Maintenance
Autonomous Maintenance Steps:2) Make FUTURE cleaning easier and faster
by:• Improving access to equipment• Eliminating sources of contamination• Establishing standard operating procedures• Making sure correct items are on hand (proper
lubricants, cleaners, etc…)
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
Productive Maintenance
Autonomous Maintenance Steps3) Basic Training
• Teach correct procedures, settings, adjustments
• Teach problem detection • Teach problem resolution
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
Productive Maintenance
Autonomous Maintenance: Housekeeping Rules1)Only necessary items at workplace2) Design locations for everything3) Keep workplace clean4) Everyone participates5) Continuous adherence
Lean Six Sigma: Process Improvement Tools and TechniquesDonna C. Summers
© 2011 Pearson Higher Education,Upper Saddle River, NJ 07458. • All Rights
Reserved.
Productive Maintenance
Productive Maintenance Takes COMMITMENT!