Lean six sigma process improvement tools and techniques by donna summers chapter 15

• Elimination of Equipment Losses: Prevent Downtime – Eliminate Breakdowns, the loss or reduction of a specified function, which cause production losses, spoilage, lost time.. Producti

Productive Maintenance

Chapter 15

– Reduce breakdowns (jams, standbys,

speed losses, startup losses, quality, etc…)

Productive Maintenance

• Where do production losses come

from?

• Quality/non conformance issues

• Raw materials shortages

• Machines or equipment availability

• Cycle time losses

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%

How will we accomplish

this?

Productive Maintenance

• There are four components to a

productive maintenance program:

– Elimination of equipment losses

– Preventive maintenance

– Predictive or planned maintenance

– Autonomous 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

Productive Maintenance

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

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

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

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

Productive Maintenance

Preventive Maintenance

– Preventive maintenance maintains the

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

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

• Establish

• Adhere to

• Review periodically

– 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?

– 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

– Repair and service reports – Maintainability improvement records

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

• Improve this by:

– Building awareness – Monitoring expenditures closely – Responding to deviations quickly

– 5) Reducing permanently stocked spare parts – 6) Using idle equipment effectively

– 7) Reducing energy and resource use

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

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

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

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

Productive Maintenance

Autonomous Maintenance Steps:

1) Thoroughly clean all equipment

• may take place during plant shutdown

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…)

• Teach problem detection

• Teach problem resolution

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

Productive Maintenance Productive Maintenance Takes COMMITMENT!