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Maintenance Mission To maximize and sustain the reliability of all manufacturing equipment and provide the capability to produce high quality products at the lowest possible cost over the life of the plant.
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Maintenance Excellence
Maintenance Excellence is a comprehensive strategy to ensure that equipment is available for production when it is needed Eliminate unplanned downtime Transition from reactive maintenance to proactive
Desired State
Preventive/Predictive Maintenance Critical spares inventory Computerized Maintenance Management Operator ownership of equipment
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PREVENTIVE/PREDICTIVE MAINTENANCE
18 17
Organization
Pride, Quality and Workmanship Facilities and Equipment Training Supervision and Practices Organization Management Reporting & Control Budgetary Control Master Plan Objectives, Goals, & Targets Status Assessment & Sustainment Maintenance Engineering Equipment History Inventory Control Work Measurement
20 19 13 12 11 10 9 8 7 1
16 15 14 6 5
Work/Job Planning Scheduling and Coordination CCMS Support Cost Distribution Work Order System Governing Principles & Concepts
Operational Control
Scorekeeping
4 3 2
Informational Sources
Program Foundation
MANAGEMENT COMMITMENT
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5% 8% 2% 3%
30%
PRODUCT COST/PRICE
SELECTION
Web Page System
DELIVERY/QA MAINTENANCE
Inventory, Assembly, Installation
PM Cycle Spare
DESIGN
Application cost, including drawings
PROCUREMENT PERFORMANCE
Transaction Freight Duty
AFTER SALE
Contract Penalties, Parts stock, Warranty
Fix Problem
Time to Complete
Proactive
PM Detect Problem Generate W/O Plan W/O
Schedule W/O
Fix Problem
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Thorough PM Program
Predictive Maintenance CMMS Integrated with Business Syst Proactive Maintenance Plg and Sched Level V
Level II
Preventive Maintenance Program Mostly Reactive Breakdown Maintenance
Level III
Preventive Maintenance Computerized Work Order System Some Predictive Maintenance
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Improve
KPIV Settings FMEA MTBF Planning & Scheduling Establish CMMS Maintenance Engineering Standard Procedures Training
Analyze
Cause & Effect Statistical Graphing Root Cause Analysis FMEA Time Series Analysis Correlation/Regression Studies Analysis of Variance
Control
Check Lists Standard Procedures Data Collection/Sampling CMMS Implementation Audits TPM Control Charts Poke Yoke Methods
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Maintenance Efficiency
Cost of Maintenance per Cost of Unit Produced Cost of Maintenance vs. Equipment Replacement Cost Schedule Compliance Percentage Overtime Worked Percentage Inventory Cost Percentage
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3) Equipment Strategy
Kaizen to achieve baseline condition PM content, frequency, responsibility, metrics
6) Operator TPM
Ownership Visual controls
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CMMS Myths More organizations are thinking seriously about the importance of reliable productionand think that the quick solution is to buy a CMMS system to reduce costs overnightA CMMS will help you do things better, but does not always focus on doing the right thingIt is a tool not an answer, and requires a champion to implement it and take it through its teething time.
Maintenance & Asset Management Magazine, May 97
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