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• A dirty work environment is
typical
• Machinery failures are
normal
• Accelerated deterioration
and abnormalities are
expected
• Operators “run” and
technicians “fix”
Conventional
Thinking
Evolution of Key Roles
0
50
% T
ime
Basic Operation
Daily Inspection
Improvement,
Small Repairs
Operator
100100
Maintenance
Breakdown Repairs0
50
% T
ime
Preventive
Maintenance
Corrective
Maintenance
Maintenance System
Management
Maintenance Techniques (FMEA, CBM)
Operation Breakdown Repairs
Care for Equipment Breakdown Elimination
Transfer Basic
Maintenance Skills
and Tasks
Integrated Model Approach
Daily Team
Maintenance
Planned
MaintenanceIntegrated Model
Equipment
StabilityDecreased
Minor Stops
Decreased
Breakdowns OEE
Increases
and Cost
Reductions
Are
Achievable
Lean
Manufacturing
DTM and PM 4-Phase Approach
Phase 1:
Reduce
Breakdowns
Phase 2:
Lengthen
Equipment Life
Phase 3:
Implement
Periodic
Maintenance
Phase 4:
Predict
Equipment Life
DTM
Steps 1-3
DTM
Step 4
DTM
Step 5
DTM
Steps 6-7
PM
Steps 1-2
PM
Step 3
PM
Step 4
PM
Steps 5-6
5S
Focused Improvement
Continuous Skills Development
Daily Team Maintenance
Who: Cross functional teams of
Operators, technicians, maintenance,
production leadership
How: 7-Step process implementation
Why: Targets losses due to minor
stops, breakdowns, changeover time
Where: Model Equipment first, then
all equipment plant wide
What: DTM Provides operators with the
knowledge and skills required to
proactively prevent breakdowns and off-
quality caused by accelerated
equipment deterioration and
abnormalities.
DTM Pillar
Team
Team Leader
M
M
M MM
M
Replication
Team 1
M
M
MM
M
Team
Lead
Replication
Team 2
M
M
MM
M
Team
Lead
8
8
7
10
6
5
5
6
7
7
0 2 4 6 8 10
CNPD
EEM
PC
QM
CSD
FI
5S
PM
DTM
SAFETY
Pillar Steps
Pillar Steps
DTM Improved Our:
•eliminated dirt, contamination & deterioration
• reduced breakdowns & downtime
•defined standards for optimal equipment
conditions
•educated operators on the identification &
repair of abnormalities
• increased operator awareness and responsibility,
& equipment knowledge
• freed up technicians to troubleshoot and
redesign
• created an environment of pride, ownership,
and responsibility
•eliminated the barrier between operators and
technicians
Equipment
People
Culture
DTM and PM 4-Phase Approach
Phase 1:
Reduce
Breakdowns
Phase 2:
Lengthen
Equipment Life
Phase 3:
Implement
Periodic
Maintenance
Phase 4:
Predict
Equipment Life
DTM
Steps 1-3
DTM
Step 4
DTM
Step 5
DTM
Steps 6-7
PM
Steps 1-2
PM
Step 3
PM
Step 4
PM
Steps 5-6
5S
Focused Improvement
Continuous Skills Development
PM Sub-Pillars
DTM SupportSpare Parts
Management
Lubrication
Management
Maintenance
Team Skills
Enhancement
Predictive
Maintenance
Preventive
Maintenance
Maintenance
Cost
Management
Zero Failure
Activities
• Zero breakdowns
• Improved reliability
• Improved maintenance
skills and capabilities
• Reduced maintenance
spend
PM Improved Our:Maintenance Process
•established a predictive and preventative maintenance system & schedule
•developed metrics around maintenance
•provided methods to analyze and understand cost
Equipment
•Provided tools to analyze, track, and document machine failures
•Eliminated root causes
• Implemented countermeasures to prevent recurrence
Associates•Provided education for technician (and operators) to raise
skills levels
•Assisted CSD pillar is DTM operator training
Roles: Operators vs Maintenance
• trouble-shoot major problems
• improve equipment by
correcting design weaknesses
• assist teams in machine
restoration and
countermeasures
• provide technical support to
operators
• educate operators to:
➢ clean
➢ tighten
➢ lubricate
➢ identify abnormalities
➢ identify deterioration
• “own” their machines
• maintain basic machine
conditions:
➢ cleaning, tightening, lubricating
• identify deterioration
• identify abnormalities before
breakdowns
• work with technicians to make
minor repairs
• participate in root cause
analysis
• develop skills/knowledge:
➢ machine function, minor repairs
➢ visual inspection, proper
operation
After
DTM/PM
• fix breakdowns and minor
stops when they occur
• “I run it, you fix it!”
• inability/knowledge to detect
and correct abnormal
conditions
Operators Technicians
Before
DTM/PM
How is it different?
Ensures Associates have:
What they need
Where they need it
When they need it
… to sustainably
eliminate inefficiencies
5S is not just housekeeping!