THE VISUALMACHINETHE VISUALMACHINE

Using lean practices and visuals on equipment help improve workplace safety, maintenance and efficiency.

2,986,500Injuries & Illnesses On The Job

Sprains, strains & tears

340,870Back

injuries

182,270Falls, slips

& trips

225,550

IN 2011, UNSAFE WORK ENVIRONMENTS LED TO...

But that’s not all. The cost of workplace injuries is also staggering:

Employer’s pay as much as

$1 BILLIONPER WEEK

in direct and indirectworker’s compensation

costs.

Costs of an Unsafe Work Environment

Curb workplace accidents by labeling equipment and areas that employers should be aware of.

RequiredLabels

SOP’s

LubeMaps

MAKING YOUR WORKPLACE & EQUIPMENT SAFE USING VISUALS

THE MAIN CAUSES OF EQUIPMENT FAILURE

ImproperLubrication

Contamination

Too little lubrication, too much lubrication or the wrong lubrica-tion can cause equipment failure.

Contaminated products, processes or environments can

cause equipment failure.

1 2

3

45

6

THE 6 BIG LOSSES FOR EQUIPMENT

• Obstructed Product Flow

• Component Jams• Misfeeds• Delivery/Sensor

Blocked• Cleaning

& Checking

• Setup/Changeover• Material/Operator Shortages• Major Adjustments• Warm-Up Time

• Rough Running• Under Name-plate

Capacity• Under Design

Capacity• Equipment Wear• Operator

Inefficiency

• Scrap• Rework• In-Process Damage• In-Process Expiration• Incorrect Assembly

• Scrap• Rework• In-Process Damage• In-Process Expiration• Incorrect Assembly

• Tooling Failures• Unplanned Maintenance• General Breakdowns• Equipment Failure

SMALL STOPS

SETUP & ADJUSTMENTS

REDUCED SPEED

PRODUCTION REJECTS

STARTUP REJECTS

BREAKDOWNS

RETURN ONINVESTMENT

Reduction inmaintenance costs

Elimination ofbreakdowns

10times

25-30% 70-75%

Reduction indowntime

Increase inproduction

35-45% 20-25%

PREDICTIVE MAINTENANCE

TRADITIONAL APPROACHES

MOVING FROM REACTIVE TO PREDICTIVE MAINTENANCE

Many companies engage in reactive maintenance, which is when you wait for a problem to show up, and then fix it. But this method can be very expensive as it results in unplanned downtime.

Innovators are now saving millions by using predictive analytics and maintenance techniques to anticipate problems before they occur.

Companies can help improve their maintenance by using

Predictive Maintenance Software.Software like LINK360™ uses the data that

manufacturers already have available, such as:

• Equipment type

• Number of days in operation

• Operating voltage

• Planned & unplanned maintenance costs

• Failure history

• Days from last/next service

• Parts analysis

...and more.

Organizing Maintenance Operation with Software

Early Equipment Maintenance focuses on using previous experiences from operators to eliminate the potential for losses through the planning, development and design stages.

For Early Equipment Maintenance, the goal is to introduce a loss and defect free process so that equipment downtime is minimal (zero

breakdowns), and maintenance costs are all considered and optimized from the start.

MOVING FROM AUTONOMOUS MAINTENANCE TO EARLY EQUIPMENT MAINTENANCE

SOURCES:

http://www.huffingtonpost.com/2012/09/11/ibm-predictive-maintenance_n_1873701.htmlhttp://www.epa.gov/lean/environment/methods/fives.htm

http://www.bls.gov/iif/http://www.reliableplant.com/Meta/Tags/lean%20manufacturing

http://www.industryforum.co.uk/practical-solutions/tpm/early-management/http://www.oee.com/oee-six-big-losses.html

www.BradyID.com/visualmachine

VISIT US TO GET A FREE Preventive Maintenance E-Book