MAINTENANCE
FROM CURATIVE TO PREDICTIVE MAINTENANCE
1. LEARN BY YOURSELF & CHALLENGE YOUR WAY OF DOING
WHY
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Guaranty and optimize the production equipment to reach the expected performances.
WHAT
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Its a system which systematically allows to detect, analyze and solve your equipment dysfunctions.
The target is to maximize and optimize the productive time.
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HOW
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I collect & measure my production performances with appropriated kpi. (productive time)
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Thanks to 5S and Gembawalks, I detect & analyze machine dysfunctions impact
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I put in place corrective maintenance to reduce dysfunctions
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I put in place preventive actions come from curative actions and machine supplier requirement.
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Put in place alert system inside my organization
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I formalize my preventive through SOP (routine)
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Deploy maintenance competencies... And focus on preventive level 1 for production and level 2 to 5 for Maintenance.
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I put in place kpi to follow my system (Maintenance cost, number of breakdown, downtime of production)
BENEFITS
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Through its mission of optimizing the operation of equipment, maintenance contributes to the creation of value for the entire organization.
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It's a source of cost reduction and overall performance.
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Reduce equipment downtime -> Increase equipment productivity (OEE) -> Increase factory capacity -> Lower Manufacturing cost ( the maintenance cost can increase but the production cost decrease )
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Increase quality rate
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Enhance job satisfaction
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Increase life of machine => Increase return on investment -> decrease CPM
2. COPY & IMPROVE ASSOCIATED BEST PRACTICES
Practice from: DPR textile
Contact:
What: curative maintenance process
Gains: to avoid bad quality due to defective machines
Assessment level:
Practice from: DPR textile
Contact:
What: preventive maintenance plan
Gains: to prevent the production line stop
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Practice from: DPR textile
Contact:
What: Predictive maintenace organization
Gains: to predict the production line stop
Assessment level:
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Practice from: DPR
Contact:
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:
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Practice from: DPR
Contact:
What: machine turnover process
Gains: to avoid old machine in poor condition in line
Assessment level:
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Practice from: DPR
Contact:
What: machine identification
Gains: to ensure appropriate maintenance to each machine
Assessment level:
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Practice from: DPR
Contact:
What: machine spare part management
Gains: to ensure the right spare part is on the right machine
Assessment level:
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Practice from: DPR
Contact:
What: safety stock of machine
Gains: to avoid too long production time lost
Assessment level:
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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:
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Practice from: External
Contact: Eric Nef
What: Importance of lock out during machine maintenance
Gains: To avoid safety issue
Assessment level: None
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4. VALIDATE YOUR SKILLS
Competency = to...
5. EVALUATE YOUR ORGANIZATION
Assessment = OPEX
Chapter = O7
6. SHARE WITH US YOUR PRACTICE
Industrial good practices community
