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What is a visual machine? It is equipment that speaks directly to the people that use it. It is intuitive and easy-to-understand. It is well maintained and reliable. A visual machine identifies key maintenance and safety instructions at a glance without confusion. See what a visual machine can do for you.
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THE VISUALMACHINETHE VISUALMACHINE
Using lean practices and visuals on equipment help improve workplace safety, maintenance and efficiency.
2,986,500Injuries & Illnesses On The Job
Sprains, strains & tears
340,870Back
injuries
182,270Falls, slips
& trips
225,550
IN 2011, UNSAFE WORK ENVIRONMENTS LED TO...
But that’s not all. The cost of workplace injuries is also staggering:
Employer’s pay as much as
$1 BILLIONPER WEEK
in direct and indirectworker’s compensation
costs.
Costs of an Unsafe Work Environment
Curb workplace accidents by labeling equipment and areas that employers should be aware of.
RequiredLabels
SOP’s
LubeMaps
MAKING YOUR WORKPLACE & EQUIPMENT SAFE USING VISUALS
THE MAIN CAUSES OF EQUIPMENT FAILURE
ImproperLubrication
Contamination
Too little lubrication, too much lubrication or the wrong lubrica-tion can cause equipment failure.
Contaminated products, processes or environments can
cause equipment failure.
1 2
3
45
6
THE 6 BIG LOSSES FOR EQUIPMENT
• Obstructed Product Flow
• Component Jams• Misfeeds• Delivery/Sensor
Blocked• Cleaning
& Checking
• Setup/Changeover• Material/Operator Shortages• Major Adjustments• Warm-Up Time
• Rough Running• Under Name-plate
Capacity• Under Design
Capacity• Equipment Wear• Operator
Inefficiency
• Scrap• Rework• In-Process Damage• In-Process Expiration• Incorrect Assembly
• Scrap• Rework• In-Process Damage• In-Process Expiration• Incorrect Assembly
• Tooling Failures• Unplanned Maintenance• General Breakdowns• Equipment Failure
SMALL STOPS
SETUP & ADJUSTMENTS
REDUCED SPEED
PRODUCTION REJECTS
STARTUP REJECTS
BREAKDOWNS
RETURN ONINVESTMENT
Reduction inmaintenance costs
Elimination ofbreakdowns
10times
25-30% 70-75%
Reduction indowntime
Increase inproduction
35-45% 20-25%
PREDICTIVE MAINTENANCE
TRADITIONAL APPROACHES
MOVING FROM REACTIVE TO PREDICTIVE MAINTENANCE
Many companies engage in reactive maintenance, which is when you wait for a problem to show up, and then fix it. But this method can be very expensive as it results in unplanned downtime.
Innovators are now saving millions by using predictive analytics and maintenance techniques to anticipate problems before they occur.
Companies can help improve their maintenance by using
Predictive Maintenance Software.Software like LINK360™ uses the data that
manufacturers already have available, such as:
• Equipment type
• Number of days in operation
• Operating voltage
• Planned & unplanned maintenance costs
• Failure history
• Days from last/next service
• Parts analysis
...and more.
Organizing Maintenance Operation with Software
Early Equipment Maintenance focuses on using previous experiences from operators to eliminate the potential for losses through the planning, development and design stages.
For Early Equipment Maintenance, the goal is to introduce a loss and defect free process so that equipment downtime is minimal (zero
breakdowns), and maintenance costs are all considered and optimized from the start.
MOVING FROM AUTONOMOUS MAINTENANCE TO EARLY EQUIPMENT MAINTENANCE
SOURCES:
http://www.huffingtonpost.com/2012/09/11/ibm-predictive-maintenance_n_1873701.htmlhttp://www.epa.gov/lean/environment/methods/fives.htm
http://www.bls.gov/iif/http://www.reliableplant.com/Meta/Tags/lean%20manufacturing
http://www.industryforum.co.uk/practical-solutions/tpm/early-management/http://www.oee.com/oee-six-big-losses.html
www.BradyID.com/visualmachine
VISIT US TO GET A FREE Preventive Maintenance E-Book
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