MAINTENANCE

FROM CURATIVE TO PREDICTIVE MAINTENANCE

1. LEARN BY YOURSELF & CHALLENGE YOUR WAY OF DOING

 

WHY

Guaranty and optimize the production equipment to reach the expected performances.

WHAT

Its a system which systematically allows to detect, analyze and solve your equipment dysfunctions.

The target is to maximize and optimize the productive time.

HOW

  1. I collect & measure my production performances with appropriated kpi. (productive time)

  2. Thanks to 5S and Gembawalks, I detect & analyze machine dysfunctions impact

  3. I put in place corrective maintenance to reduce dysfunctions

  4. I put in place preventive actions come from curative actions and machine supplier requirement.

  5. Put in place alert system inside my organization

  6. I formalize my preventive through SOP (routine)

  7. Deploy maintenance competencies... And focus on preventive level 1 for production and level 2 to 5 for Maintenance.

  8. I put in place kpi to follow my system (Maintenance cost, number of breakdown, downtime of production)

BENEFITS
  • Through its mission of optimizing the operation of equipment, maintenance contributes to the creation of value for the entire organization.

  • It's a source of cost reduction and overall performance.

  • Reduce equipment downtime -> Increase equipment productivity (OEE) -> Increase factory capacity -> Lower Manufacturing cost ( the maintenance cost can increase but the production cost decrease )

  • Increase quality rate

  • Enhance job satisfaction

  • Increase life of machine => Increase return on investment -> decrease CPM

 

2. COPY & IMPROVE ASSOCIATED BEST PRACTICES

Practice from: DPR textile

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What: curative maintenance process

Gains: to avoid bad quality due to defective machines

Assessment level

Practice from: DPR textile

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What: preventive maintenance plan

Gains: to prevent the production line stop

Practice from: DPR textile

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What: Predictive maintenace organization

Gains: to predict the production line stop

Assessment level

Practice from: DPR

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What: Skilled people to repair machine breakdown

Gains: to avoid satefy risks and get efficient repairs

Assessment level

Practice from: DPR

Contact:

What: Breakdown Pareto and action plan

Gains: to decrease breakdown rate

Assessment level

Practice from: DPR 

Contact

What: create breakdown report

Gains: to enable breakdown analysis

Assessment level

Practice from: DPR 

Contact

What: machine turnover process

Gains: to avoid old machine in poor condition in line

Assessment level

Practice from: DPR

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What: machine identification

Gains: to ensure appropriate maintenance to each machine

Assessment level

Practice from: DPR

Contact

What: machine spare part management

Gains: to ensure the right spare part is on the right machine

Assessment level

Practice from: DPR

Contact

What: safety stock of machine

Gains: to avoid too long production time lost

Assessment level

Practice from: DPR

Contact

What: preventive machine maintenance schedule

Gains: to anticipate breakdown

Assessment level

Practice from: DPR

Contact

What: spare part safety stock

Gains: to ensure availability of spare part

Assessment level

Practice from: DPR

Contact

What: self machine inspection by worker (autonomous)

Gains: to minimize breakdown during the production line

Assessment level

Practice from: External

Contact: Eric Nef

What: Importance of lock out during machine maintenance

Gains: To avoid safety issue

Assessment level: None

3. GO FURTHER WITH OUR COACHING OFFER

Please contact: ACL factory

 

4. VALIDATE YOUR SKILLS

Competency = to...

 

5. EVALUATE YOUR ORGANIZATION

Assessment = OPEX

Chapter = O7

 

6. SHARE WITH US YOUR PRACTICE

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