If you have been trying to think about how you can improve the reliability of your machines, then these 10 steps will help.
Buy: a copy of the book “World Class Maintenance” by Terry Wireman and review the assessment found at the front of it with your comptroller, production manager and plant manager. Once you have totaled the score, you will know where you stand then you can move on to the next steps.
Rank the Asset: Based on the risk, rank the assets you consider key. Some of the questions to ask yourself as you create your list include; ‘how would plant capacity be affected if this asset stopped working?’ You may also ask, ‘if the asset does not work for as many as 24 hours, what will be the result?’
Create work orders for preventative and emergency maintenance to be carried out on the assets listed no 1 and 2 in order of priority.
Find condition: Now that you have identified the assets that carry the highest risks, find the one in the worst condition and begin to restore it step by step. Additionally, put in place preventive maintenance and operator maintenance procedures.
Create maintenance procedures: Once you are done with restoring and repairing, create corrective maintenance procedures. They should include specifications, special tools, steps, drawings and estimated hours of labor.
Apply 10% rule: Now that you have preventive maintenance procedures, adhere to them and apply the 10% rule. This means that if the maintenance is carried out every 30 days in order to be compliant, the maintenance must be completed within a period of 3 days.
Sight warning: Put up a sight warning that the area where the equipment is located is a proactive maintenance area and as such, only the very best maintenance operators and personnel can work in the said area.
Graph the trend: Make sure that you have overall equipment effectiveness metrics in place for the area where production happens. Then daily graph the OEE to show how the trend is going.
Develop a metric that measures vendor performance. It should have 3 parts as follows:
- How many times the vendor delivers the parts you need on time. It should be reflected as a percentage.
- How many times this vendor delivers a part that is not what you agreed on also as a percentage.
- How many times this vendor delivers the right parts in the wrong quantity.
By measuring these 3 metrics, you will be able to get the vendors’ performance. Anything under 95% is not acceptable.
Look at the results you got when you did your assessment based on Terry Wireman’s book and begin working on your maintenance process right from planning on to scheduling. If all these steps are too complicated for you, or you just don’t have the time nor the resource to do it, make sure you check out our RAM projects.