productive maintenance

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Lean Six Sigma: Process Improvement Tools and Techniques Donna C. Summers © 2011 Pearson Higher Education, Upper Saddle River, NJ 07458. • All Rights Reserved. Productive Maintenance Chapter 15

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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 Presentation

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Page 1: 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 MaintenanceChapter 15

Page 2: 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

• Vision: Total life cycle equipment management– Seeks to measure and improve overall

equipment effectiveness

Page 3: 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

• Benefits– Reduce costs– Reduced inventories– Reduce lead-time– Reduce injuries– Reduce breakdowns (jams, standbys,

speed losses, startup losses, quality, etc…)

Page 4: 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

• Benefits– Improved customer satisfaction– Improved productivity– Improved work environment– Improved quality– Improved change-over times

Page 5: 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

• Benefits– Eliminate Waste

• Wasted Time• Wasted Resources

Page 6: 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

• Where do production losses come from?

• Quality/non conformance issues• Raw materials shortages• Machines or equipment availability• Cycle time losses

Page 7: 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

• Productive Maintenance seeks to improve Overall Equipment Effectiveness (OEE)

OEE = Availability x efficiency x quality

– OEE is typically 50-60%, can climb to 80%

Page 8: Productive Maintenance

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?

Page 9: 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

• There are four components to a productive maintenance program:– Elimination of equipment losses– Preventive maintenance– Predictive or planned maintenance– Autonomous maintenance

Page 10: Productive 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

Page 11: 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

Page 12: 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 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

Page 13: 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: 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

Page 14: 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• 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

Page 15: 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

Preventive Maintenance– Preventive maintenance maintains the

equipment in good condition so that unexpected downtime does not occur.

Page 16: 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

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

Page 17: 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

Preventive Maintenance1) Perform Long term Maintenance

• Plan• Schedule• Execute

2) Create Standards• Establish • Adhere to• Review periodically

Page 18: 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

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?

Page 19: 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 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

Page 20: 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

Preventive Maintenance4) Maintain Records

• What records are needed?• Why needed?• How used?

Page 21: 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

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

Page 22: 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

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

Page 23: 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

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

Page 24: 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

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

Page 25: 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

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

Page 26: 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

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

Page 27: 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

Predictive Maintenance– Predictive maintenance schedules routine

maintenance so that everyone knows and can plan for a machine or a piece of equipment being unavailable.

Page 28: 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

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

Page 29: 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

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

Page 30: 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

Predictive MaintenanceMaintenance Skill Training– Maintenance

• Workers with strong maintenance and equipment related skills

• An understanding of equipment• Develop expertise and skills

Page 31: 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

Autonomous Maintenance– Performed by equipment operators

• Daily cleaning, inspecting, lubricating, bolt tightening; prevents equipment deterioration.

• 15 min/day• Transfers ownership to person running

machine

Page 32: 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 MaintenanceAutonomous Maintenance Steps:

1) Thoroughly clean all equipment • may take place during plant shutdown

Page 33: 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

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…)

Page 34: 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

Autonomous Maintenance Steps3) Basic Training

• Teach correct procedures, settings, adjustments

• Teach problem detection • Teach problem resolution

Page 35: 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

Autonomous Maintenance: Housekeeping Rules1)Only necessary items at workplace2) Design locations for everything3) Keep workplace clean4) Everyone participates5) Continuous adherence

Page 36: 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

Productive Maintenance Takes COMMITMENT!