Reliability Will Put your Competition to Rest
22
Creating a Company that would Put Yours out of Business! Visual Maintenance
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What Visual Maintenance and Reliability can do to improve your organization.
Transcript of Reliability Will Put your Competition to Rest
Creating a Company that would Put Yours out of
Business!
Visual Maintenance
If you are not a World Class Maintenance Organization…
Being World Class Doesn’t cost you more Money! It actually cost you less!
You won’t need to be - You’ll soon be Out of Business
Truths About U.S. Manufacturing!
At this time there is an estimated loss of $750 Billion due to breakdown maintenance (reactive) or generally poor, incorrect or excessive practices. SMRP Solutions June 2010
SO WHY DOESN’T ALL MANUFACTURERS HAVE
WORLD CLASS MAINTENANCE PROGRAMS?
SO WHY DON’T YOU HAVE A WORLD CLASS MAINTENANCE PROGRAMS?
Vision
Value
Control
Feedback
Reactions to what gets your attention!
Execution Results
Management Leadership Initiatives
Corporate Resources
Third Party Resources
Command and Control Feedback Loop (Fire Fighting)
Copyright © 2009 RightFoot Technology Inc. All Rights Reserved
On Delivery! On Maintenance! On Quality!
Impact On Profits! Competitiveness!
Myth: Don’t have time to be proactive. But, what is the cost of being reactive?
From my Vantage Point, You Don’t have
time not to Be Proactive!
Is faster Better?
Is “More” Better
Just another Quick Fix
The 4/5 Rule
Myth: Faster is better! So how fast is fast enough?
From my Vantage Point,
Slower is Faster!
Yesterday’s Value won’t make tomorrow's sales! We need a different context to win!
With a Vision-2-Value Viewing Point You:◦ See problem from a larger perspective
◦ Focus on the little things that make the big difference – Leverage Points
◦ Activities are accomplished with a goal centric point of view: Delivering: VALUE, VALUE, VALUE...
Looking from a Different Viewing Point (Step 2 of Cultural Change)
Vision
Value
Goals
Measures & Commits
Metric Reviews
Control
Feedback
On-Course Correction
Execution Metrics
Management Leadership Initiatives
Corporate Resources
Third Party Resources
Corporate and CommunityDashboard
Command and Control Feedback Loop
Copyright © 2009 RightFoot Technology Inc. All Rights Reserved
Clarity
Accountability
Alignment - Balance
Visual Maintenance is all About
What Does Your maintenance Program Look Like?
RM
RM
RM
RM
RM
Reactive Maintenance
SM
SM
SM
Scheduled Maintenance
PM
PM
Predictive Maintenance
BALANCE
Machine Optimization
Optimized Performance for a Category of Machines
A complete Plant Overhaul
Targeted Custom Solutions
Visual Maintenance SolutionsDelivering IMPROVED Performance on the Floor
Single Solution for One Machine - Bush Press
Mfg. Capacity 1500 parts per shiftCurrent Capacity 400 parts per shiftAvg. DT 2 hr./weekMfg. EOL 24 weeksActual 3 daysCritical Part 2 sets on hand
Current 8 sets
Cost-of Care $8,372.12 6mo. 2 sets of grippersThreshold Mgmt 45% below threshold
Gripper CostsProblem Alignment Brass $1,965.29
Solution
Re-Align the robot pick-up arm to the nest Steel $2,534.12
The reliability of the grippers are at 98% reliability after the first hour of operation. Given there were two different sets that failed at 48 hours and 52 respectively. The manufacturer informed us that the
grippers (Brass) would last 24 weeks or the reliability was 576 hours(expect to fail). Instead given our specified cycle time of 50 parts per hour, the MTBF(MTTF) was 50 hours, ironically.
Single Solution for One Machine - Bush Press Solution
Mfg. Capacity 1500 parts per shiftCurrent Capacity 1000 parts per shift SavingsAvg. DT 0.25 hr./week $7160Mfg. EOL 24 weeksActual 6 weeksCritical Part 2 sets on hand
Current 8 sets
Cost-of Care $11.75 1 week Check for alignment and worn grippersThreshold Management 100% at threshold
Gripper CostsProblem Alignment Brass $1,965.29
Solution
Re-Align the robot pick-up arm to the
nestSteel $2,534.12
The reliability of the grippers are at 98% reliability after the first hour of operation. Given there were two different sets (Brass and Steele) that failed at 48 hours and 52 respectively. The manufacturer
informed us that the grippers (Brass) would last 24 weeks or the reliability was 576 hours(expect to fail). Instead given our specified cycle time of 50 parts per hour, the MTBF(MTTF) was 50 hours, ironically. After solution the grippers reliability factor was at 144hours, still below manufactures
reliability factor, after training the operator the reliability improved by 20%.
Cost, Capacity and Threshold Management Dashboards
Visual Maintenance Dashboards
Maintenance Technician Contribution Dashboards
Custom Dashboards
Visual Maintenance SolutionsShow IMPROVED Performance Across the Organization
On-The-Floor Maintenance Solutions
Managed Care Dashboard Solutions
Goal Centric Driven Solutions
Custom Dashboards to fit your specific Requirements
Can Guide your Reliability Journey
What We Do - SummaryWe Drive DOWN Costs!
Visual Maintenance is Results you can
SEE!
In Closing we would Like to Challenge each of you to…
THINK
From a Different Viewing Point!
Because…
Today You are IN Business
Tomorrow You could Be OUT of Business
Questions?
