Predictive MaintenanceWhat is the prize?
Degree of difficulty is on the rise Reduce marketplace redundancy The enemy is unplanned DT The prize is contribution to revenue
Predictive MaintenanceRequires a culture change
PM is not tangible Not just sending someone to karate class Every person in Operations must be
involved Mission for each department must be
understood Effective questioning We have branded our culture change
Force Field Predictive Maintenance and
Management System
1) Management Philosophy2) Predictive Maintenance Program
Accountability EnginePosition
Critical Responsibility Standard Control
Insert Operator
Insert machine productivity
Meeting the standard as established by the zone supervisor in the pre-shift meeting. Remember a standard means that anything less is unacceptable. A goal is always higher than a standard and is indicitive of exceptional performance.
Packaging Stats Report (A)
Responsibility ZonesZONE 1 4 operators ZONE 2 3 operators
D Press C Press Winder 1 B Press A PressLine Line Line Line
Winder 2Op
Winder 3
Winder 4
Op Op Op Op OpGMA 1 GMA 2 GMA 3 GMA 4 GMA 5 GMA 6
Op 3 operators ZONE 2 Op
TL 1 TL 2 TL 3 TL 4 TL 5 TL 6 TL 7 TL 8 TL 9 TL 10
CL 1 CL 2 CL 3 CL 4 CL 5 CL 6 CL 7 CL 8 CL 9 CL 10
Control ReportName: Edition: Product: Zone Plan: 2-person 3-person Zone: 1 2 3
Preshift Topics
Back-line Leader:Cartloader pre-run check performed properly
Maintained cartloaders properly
Radio called equipment problems properly
Directed work of tie-line and QC personnel
Immediate notification if procedure violated
Kept work area safe
QC Personnel: Communicated all quality issues to Insert Op.
P F P F P F P F P F P F P F
2 x's per hour
As needed
2 x's per hour
As needed
1 x per hour
Beginning of shift P F
1 x per hour P F P F P F P F P F P F P F
Procedure Execution Control
(P)ass or (F)ail
Position Responsibility Audit Frequency Audit Result
Knowledge Sharing Sessions
Engineers FF
In
tro
du
cti
on
Date
Co
mp
lete
d
Ho
w t
o A
vo
id P
inch
ed
Bra
ke W
ires
Date
Co
mp
lete
d
Ho
w t
o R
ead
Oscillo
sco
pe W
ave F
orm
s
Date
Co
mp
lete
d
Su
n P
rin
tin
g a
nd
Packag
ing
Pla
n
Date
Co
mp
lete
d
CT
P
Brian Boddy FF 2/6/07 FF 2/22/07 FF 3/6/07 G 3/20/07 EPat Sweeney FF Vac. FF 2/27/07 FF 3/13/07 G 3/27/07 ETim Aguier FF 2/6/07 FF 2/20/07 FF 3/6/07 G 3/20/07 E
Predictive Maintenance
Complete 2/6/07
Force Field TeamSeal of Approval
Force Field Predictive Maintenance Team
Qua
lity
and
Acc
urac
y is
Our
Pas
sion T
hank You for Y
our Contribution
Operations Division
Force Field RulesDecisions based on objective
feedbackNo complaining - useable ideas onlyNo assumptions
Force Field Steps
DT Analysis
Prioritized DT Problems
Isolate Failure Area
Determine Failure Component
Determine Control Point
Develop Troubleshooting Technique
Determine Acceptable Operating Parameters
Implement Improvement Procedure
Implement Result Monitoring of Improvement Procedure
Install Force Field Predictive Technique
Install Feedback on Force Field Violation
DT Tracking
Bucket Tracking
Determine Procedure Prob. from Holes in FF
Pub Date
Pub Day Run Presses
Planned Stops
Planned DT per Stop
Total Planned
DTActual
DTUnplanned
DT7/1/07 Sun Main 4 2 10 20 116 967/2/07 Mon Main 4 2 10 20 84 647/3/07 Tue Main 4 4 10 40 77 377/4/07 Wed Main 4 3 10 30 162 1327/5/07 Thu Main 3 2 10 20 72 527/6/07 Fri Main 3 4 10 40 60 207/7/07 Sat Main 3 2 10 20 93 737/8/07 Sun Main 4 3 10 30 102 727/9/07 Mon Main 3 3 10 30 55 25
7/10/07 Tue Main 3 3 10 30 70 407/11/07 Wed Main 4 6 10 60 136 767/12/07 Thu Main 3 3 10 30 82 527/13/07 Fri Main 3 3 10 30 122 927/14/07 Sat Main 3 3 10 30 67 377/15/07 Sun Main 4 4 10 40 80 407/16/07 Mon Main 3 3 10 30 68 387/17/07 Tue Main 3 3 10 30 64 347/18/07 Wed Main 4 4 10 40 75 357/19/07 Thu Main 3 3 10 30 71 417/20/07 Fri Main 3 5 10 50 44 -67/21/07 Sat Main 3 2 10 20 89 697/22/07 Sun Main 4 5 10 50 84 347/23/07 Mon Main 3 3 10 30 95 657/24/07 Tue Main 3 3 10 30 87 577/25/07 Wed Main 4 4 10 40 74 347/26/07 Thu Main 3 3 10 30 55 257/27/07 Fri Main 3 2 10 20 62 427/28/07 Sat Main 3 4 10 40 73 337/29/07 Sun Main 4 5 10 50 216 1667/30/07 Mon Main 3 3 10 30 34 47/31/07 Tue Main 3 3 10 30 75 45
Avg # of Presses 3.4 1020 2644 1624Total Hours 27
Pub DatePub Day
Unplanned DT Mechanical Electrical Consumable
Human (Pressroom)
Human (Maint Dept) Packaging Unknown Total
7/1/07 Sun 96 91 5 967/2/07 Mon 64 51 13 647/3/07 Tue 37 24 7 6 377/4/07 Wed 132 25 107 1327/5/07 Thu 52 48 4 527/6/07 Fri 20 16 4 207/7/07 Sat 73 62 11 737/8/07 Sun 72 8 64 727/9/07 Mon 25 13 4 8 257/10/07 Tue 40 4 36 407/11/07 Wed 76 46 21 9 767/12/07 Thu 52 14 13 12 13 527/13/07 Fri 92 15 46 8 1 22 927/14/07 Sat 37 37 377/15/07 Sun 40 13 27 407/16/07 Mon 38 8 6 5 19 387/17/07 Tue 34 16 1 17 347/18/07 Wed 35 13 22 357/19/07 Thu 41 11 15 15 417/20/07 Fri -6 -6 -67/21/07 Sat 69 16 46 7 697/22/07 Sun 34 20 14 347/23/07 Mon 65 50 15 657/24/07 Tue 57 56 1 577/25/07 Wed 34 2 29 3 347/26/07 Thu 25 11 14 257/27/07 Fri 42 42 427/28/07 Sat 33 15 18 337/29/07 Sun 166 15 35 56 60 1667/30/07 Mon 4 4 47/31/07 Tue 45 23 22 45
Minutes 1624 108 249 105 719 13 70 360 1624Percent 100% 7% 15% 6% 44% 1% 4% 22% 100%
Occurances 6 8 6 30 2 4 18 31Avg Min. per Occurance 18 31 18 24 7 18 20
Departmental Contribution to Unplanned DowntimeMinutes Percent
370 23% Predictive Maintenance Department824 51% Pressroom70 4% Packaging
360 22% Unknown1624 100%
Department
Main Edition - Sunday 7/1/07
Bucket Area Position Status Symptom Mill SpecRTP
Tension
Split Tower/
Split Sheet or Bar Lead Cause
Sub Cause Min.
Electrical B - Folder - Roll-up
Lost communic
ation - - - -Folder
Cabinet
Power supply failure 91
Human (Pressroom) A MIC Stopped - - - - -
Edition Change
Longer than
budget 1
Human (Pressroom) C MIC Stopped - - - - -
Edition Change
Longer than
budget 496
Main Edition - Monday 7/2/07
Bucket Area Position Status Symptom Mill SpecRTP
Tension
Split Tower/
Split Sheet or Bar Lead Cause
Sub Cause Min.
Human (Pressroom)
A 5-Tower A
Level Unit Start-upImpressions not on - - - - Switch
Impression
switch off 1
Unknown Unknown -Running at speed
Break - RTP B-6 Kruger Perfect 50 N/N
Unknown
Unknown 13
Human (Pressroom) Folder MkRdy Start-up
Detector shut-down - - - -
Detector
Out of alignme
nt 3
Human (Pressroom) RTP C-3 MkRdy
Running at speed
Break - RTP C-3 - - - - Belt
Not locked
in 4764
Main Edition - Sunday 7/1/07
Bucket Cause Sub Cause
PM In Place (Y/N)
If "Y" Date Done
If "Y" by
Whom
# of Component Failures on
RecordTime
Period
Mean Time
Between Failure
Predictive Maintenance Improvement
Action
Electrical Folder CabinetPower supply
failure N - - 8 2 yrs 3 months Replace all
Main Edition - Monday 7/2/07
Bucket Cause Sub Cause
PM In Place (Y/N)
If "Y" Date Done
If "Y" by
Whom
# of Component Failures on
RecordTime
Period
Mean Time
Between Failure
Predictive Maintenance Improvement
ActionNo
opportunities
Date DepartmentForce Field
Holes
Person or Position
Accountable Standard ControlDate
Started Status
8/1/07 Pressroom
Need person responsible for web detectors Make ready
Every active detector checked and problems are radio'd to engineers
Force field downtime report 9/1/07
Machinists making detector guages
8/14/07 Pressroom
Need person responsible for insuring the sheet is being pulled straight through the press Bob Dags
Each press checked every night and actions taken to correct problems
Force Field square sheet report
8/18/07 Maintenance
Need person responsible for troubleshooting standards D. Borom
8/20/07 Maintenance
Track manufacturer and date RTP belts were changed D. Borom
Every belt is tracked
Force Field RTB belt control report 8/21/07
8/20/07 Pressroom
Need person responsible for finding paster patterns that broke and evaluating the cause Bob Dags
A Press
RtpFirst
ScopeBrake Job
Pinched Wire
Carriage belts
Dancer
Cylinder
Dancer Pot.
Pot. Carrier
Slip Rings
3 4/26/07DC
8/16/07Nitta / Blue 8/15/07 8/15/07 CLEAN 8/16/07
4 4/26/07 1/4/2007 OKNitta
9/5/07 4/24/07 5/3/07 CLEAN 4/27/07
5 3/3/07DC
5/8/07 YESNitta
3/14/07 3/6/07 3/6/07 TAPE/CL 3/8/07
5a 6/24/07DC
9/12/07Nitta
9/12/07 8/15/07 8/15/07 CLEAN 9/13/07
6a 3/15/07DC
5/24/07 OKNitta
9/12/07 4/19/07 4/3/07 TAPE/CL OK
6 3/4/07 3/20/2007 YES / 5Nitta / Blue 3/20/07 3/20/07 TAPE/CL 3/20/07
7 2/19/07DC
4/18/07 YESNitta
9/12/07 2/21/07 2/21/07 RUST OK
8DC
9/12/07Nitta
9/12/07 8/15/07 8/15/07 CLEAN 9/13/07
Rtp
Slip Ring
BrushesWarner
AdjWarner
ReplMotoriz'd Reg.
Transducer
Volume Booster
1395 Drive
Final scope
3 8/16/07 8/15/074 4/27/07 511/07 5/16/07 4/24/07 4/24/07 4/24/07 OK 6/19/075 3/8/07 3/14/07 3/9/07 3/7/07 3/6/07 3/7/07 3/20/07 3/16/07
5a 9/13/07 8/15/076a 4/4/07 OK 4/19/07 4/3/07 4/3/07 OK6 3/20/07 OK CAL. 3/21/07 3/21/07 3/20/07 4/25/077 3/2/07 3/14/07 4/19/07 CAL. OK 2/21/07 OK 4/21/078 9/13/07 6/26/07 8/15/07 6/27/07
Reducing Unknown DT Dancer positionDover roller tensionFolder and unit detectorsPaster brush, bell and knifeUnit severers