Productive Maintenance Chapter 15 LeanSixSigma:ProcessImprovementToolsandTechniques DonnaC.Summers â2011PearsonHigherEducation, UpperSaddleRiver,NJ07458.AllRightsReserved Productive Maintenance • Vision: Total life cycle equipment management – Seeks to measure and improve overall equipment effectiveness 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 • 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 Techniques DonnaC.Summers â2011PearsonHigherEducation, UpperSaddleRiver,NJ07458.AllRightsReserved Productive Maintenance Benefits Improved customer satisfaction – Improved productivity – Improved work environment – Improved quality Improved change-over times LeanSixSigma:ProcessImprovementToolsandTechniques DonnaC.Summers â2011PearsonHigherEducation, UpperSaddleRiver,NJ07458.AllRightsReserved Productive Maintenance • Benefits – Eliminate Waste • Wasted Time Wasted Resources LeanSixSigma:ProcessImprovementToolsandTechniques DonnaC.Summers â2011PearsonHigherEducation, UpperSaddleRiver,NJ07458.AllRightsReserved Productive Maintenance • Where production losses come from? • Quality/non conformance issues • Raw materials shortages • Machines or equipment availability Cycle time losses LeanSixSigma:ProcessImprovementToolsandTechniques DonnaC.Summers â2011PearsonHigherEducation, UpperSaddleRiver,NJ07458.AllRightsReserved 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 Techniques Donna 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 Techniques Donna 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 LeanSixSigma:ProcessImprovementToolsandTechniques DonnaC.Summers â2011PearsonHigherEducation, UpperSaddleRiver,NJ07458.AllRightsReserved Productive Maintenance 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 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 Preventive Maintenance 4) Maintain Records • Simplify and Standardize Current RecordKeeping Procedures – – – – – MTBF analysis Equipment Logs Maintenance Cost Records Breakdown analysis records Downtime occurrences and time LeanSixSigma:ProcessImprovementToolsandTechniques DonnaC.Summers â2011PearsonHigherEducation, UpperSaddleRiver,NJ07458.AllRightsReserved 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 LeanSixSigma:ProcessImprovementToolsandTechniques DonnaC.Summers â2011PearsonHigherEducation, UpperSaddleRiver,NJ07458.AllRightsReserved Productive Maintenance Preventive Maintenance 6) 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 LeanSixSigma:ProcessImprovementToolsandTechniques DonnaC.Summers â2011PearsonHigherEducation, UpperSaddleRiver,NJ07458.AllRightsReserved Productive Maintenance Preventive Maintenance 6) 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 LeanSixSigma:ProcessImprovementToolsandTechniques DonnaC.Summers â2011PearsonHigherEducation, UpperSaddleRiver,NJ07458.AllRightsReserved Productive Maintenance Preventive Maintenance 7) 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 Techniques Donna 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 LeanSixSigma:ProcessImprovementToolsandTechniques DonnaC.Summers â2011PearsonHigherEducation, UpperSaddleRiver,NJ07458.AllRightsReserved 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 LeanSixSigma:ProcessImprovementToolsandTechniques DonnaC.Summers â2011PearsonHigherEducation, UpperSaddleRiver,NJ07458.AllRightsReserved 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 Techniques Donna C. Summers © 2011 Pearson Higher Education, Upper Saddle River, NJ 07458. • All Rights Reserved Productive Maintenance Predictive Maintenance Maintenance 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 Techniques Donna 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 LeanSixSigma:ProcessImprovementToolsandTechniques DonnaC.Summers â2011PearsonHigherEducation, UpperSaddleRiver,NJ07458.AllRightsReserved Productive Maintenance Autonomous Maintenance Steps: 1) Thoroughly clean all equipment • may take place during plant shutdown LeanSixSigma:ProcessImprovementToolsandTechniques DonnaC.Summers â2011PearsonHigherEducation, UpperSaddleRiver,NJ07458.AllRightsReserved 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 Techniques DonnaC.Summers â2011PearsonHigherEducation, UpperSaddleRiver,NJ07458.AllRightsReserved Productive Maintenance Autonomous Maintenance Steps 3) Basic Training • Teach correct procedures, settings, adjustments • Teach problem detection Teach problem resolution LeanSixSigma:ProcessImprovementToolsandTechniques DonnaC.Summers â2011PearsonHigherEducation, UpperSaddleRiver,NJ07458.AllRightsReserved Productive Maintenance Autonomous Maintenance: Housekeeping Rules 1)Only necessary items at workplace 2) Design locations for everything 3) Keep workplace clean 4) Everyone participates 5) Continuous adherence 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 Productive Maintenance Takes COMMITMENT! Lean Six Sigma: Process Improvement Tools and Techniques Donna C. Summers © 2011 Pearson Higher Education, Upper Saddle River, NJ 07458. • All Rights Reserved ... 80% LeanSixSigma:ProcessImprovementToolsandTechniques DonnaC .Summers â2011PearsonHigherEducation, UpperSaddleRiver,NJ07458.AllRightsReserved How will we accomplish this? LeanSixSigma:ProcessImprovementToolsandTechniques... spoilage, lost time – Avoid Stops, Jams and Standbys that occur randomly and cause production lost time LeanSixSigma:ProcessImprovementToolsandTechniques DonnaC .Summers â2011PearsonHigherEducation,... with strong maintenance and equipment related skills • An understanding of equipment Develop expertise and skills LeanSixSigma:ProcessImprovementToolsandTechniques DonnaC .Summers â2011PearsonHigherEducation,