Early Equipment Management Workshop

  • EEM is not just an Engineering activity but the collective effort with plant technicians,  operators,  crafts, supervisors, etc.
  • EEM learning’s are best obtained with one to one discussions with shop floor personnel.
  • EEM must become part of the Capital Expenditure process with acknowledgement of EEM consideration similar to Safety and Environmental input.
  • The EEM team will address speed to market in all our efforts, knowing the extra up front time it takes to do EEM right.

Early Equipment Management Goals

  • Design production equipment which is easy to use, easy to maintain, highly reliable and well-engineered.
  • Reduce the time from equipment development to production and achieve ‘vertical start-up’

Long Start-up Period

  • Lots of teething troubles
  • Time to transfer operation skills
  • Lack of detail
  • Little operational input

Difficult to sustain & improve

  • Machines worn after warranty period
  • Insufficient daily maintenance
  • Continuous introduction of new material/product
  • Slow skill “catch-up”

 

Causes of Poor Start-up: 4M’s

  • Man
  • Machine
  • Methods
  • Materials
  • Other

4 M’s “Man”

Skill

  • lack of training
  • high level of technology

Organization

  • insufficient involvement of factory personnel in design
  • lack of resources

Communication

  • language
  • no structured process

4M’s “Machine”

Design

  • no feedback of improvements
  • insufficient consideration of ease of operation, maintenance
  • insufficient standardization
  • unreliable parts, special parts

Installation

  • misalignment
  • missing, damaged parts

Supplier

  • lack of operational knowledge
  • reluctance to incorporate operational knowledge

4M’s “Methods”

Schedule

  • no time for design modification
  • poor scheduling & resource allocation (commissioning)
  • delay in procuring

Procedure

  • no standard for commissioning
  • insufficient manuals
  • unclear handover conditions

4M’s “Materials”

Design

  • insufficient consideration of machine dynamics and accuracy
  • packaging design change after fixing machine specification

 

Quality control

  • poor source inspection
  • defective materials
  • poor control (storage) of materials

4M’s “Other”

Budget

  • insufficient for design modification

Demands

  • insufficient forecasts for future uncertainties

Early Equipment Management Goals

Vertical Start-up

  • Short start-up period
  • High OEE% that increases steadily

Equipment must be /have:

  • Intrinsically reliable design
  • Cleaning lubrication inspection standards for AM&PM
  • Audit checklists
  • Easy to clean, inspect, lubricate and change-over
  • Easy to maintain and repair
  • Easy to operate (fail-safe)
  • Easy to obtain data for predictive maintenance and for further improvement

People must have obtained the skills for operation, maintenance and improvement of equipment

Key Activities in EEM

Collect Maintenance Prevention  Information

Maintenance Prevention Design

  • Safety Activities

Initial Flow Control

Project Management

  • Commissioning
  • Measures

– 30/90 Day Post Completion Audit

-Launching Costs

EEM Process

MP Information & MP Design

Collect (MP) information about issues with previous equipment designs and use this data to improve the (MP) design of new equipment

MP function design

  • ease of operation, maintenance, monitoring, and safety

Loss-free design

Effective feedback of operational knowledge

communication between equipment designer and operators/maintenance staff

  • tequipment designer does not usually have sufficient knowledge on operation/maintenance

set-up of procedures for gathering MP information

apply the MP information into new equipment design and standards

Maintenance Prevention Information

MP information is :

“Operational information obtained by conducting technological studies which classify and continuously refine improvements. Such improvements with associated plant history and design modification should be readily transferable”.

MP Information

SOP (Standard Operating Procedure)

Changeover procedure

One-point lesson sheet

Current major losses

Trouble records

Maintenance records

Improvement records

Effective maintenance procedure

Parts (consumption) records

MP (Maintenance Prevention) sheet

Why/why, PM analysis etc.

Technical report

Quality report

Check sheet (design, spec., commission.)

Commissioning report

Cleaning procedure

Lubrication procedure

Inspection procedure

QC procedure

Suggestion

Commissioning report

Skill map

Training procedure, materials

MP info: Technical reports Best Proven Practice

MP Info: Visual management improvements. Easy inspection, cleaning, lubrication

MP Info: Trouble records – design faults

MP Info: Commissioning reports

MP info: Improvement records

General

  • Easy to understand
  • Qualitative
  • Drawing / picture
  • Transferable

Calculation

  • Loss
  • Cost
  • Benefits

Classification

  • Loss
  • MP function
  • Machine / Products

Information level

Good example?

 

MP Info: Improvement Records Classification

Classification

Loss

  • Breakdown / minor stoppage / set-up & adjustment / speed / defect & rework

MP function

  • Safety / operability / reliability / maintainability – autonomous maintenance / audit/ economy / quality / friendliness to environment, people

Machine / Products

  • Supplier / specification
  • Products / property etc.

Information level

  • Horizontal replication / standardization / training / permanent countermeasure

MP Info: Improvement Records Loss / Cost Calculation

Loss

Losses (less than once / year)

  • Production stop (hr / min)
  • Rework / scrap (ton / unit)
  • Defects / complaints (ton / unit / no. of complaints)

Other Losses

  • Losses x frequency (times/year)

Reduced speed

  • (Specified – reduced speed) x duration

Cost

–Man-hour to fix troubles

–Parts cost

–Subcontractor, equipment supplier costs etc.

MP Info: Improvement Records Benefits

Benefits

Production capacity increase

Man-hour reduction

Cost reduction

  • rework / scrap
  • inspection
  • parts
  • subcontractor

Example

– Breakage of parts

  • once / month
  • 3 hr for change
  • parts cost $20

– Change of materials & design

  • once / year
  • 3 hr for change
  • parts cost $20

Man-hour reduction

  • 3 hr x 12 – 3 hr x 1 = 33 hr

Production capacity increase

  • 33 hr / 5,000 hr(available time) = 0.66 %

Cost reduction

  • $20 x $12 – $30 = $210

Maintenance Prevention Design

MP design is:

“ The use of the latest maintenance data and technology when planning or building new equipment to promote greater reliability,maintainability,economy, operability and safety while minimizing maintenance costs and deterioration related loss”.

MP Design: 3 Objectives

Main Function Design

  • in order to meet current, future requirements for equipment in terms of quality, cost, capacity, flexibility and safety.

MP Function Design

  • incorporates ease of monitoring, operating and maintenance so that operators can easily improve the equipment, and identify and solve problems.

Loss-free Design

  • to eliminate 16 major losses, such as start-up, breakdown, minor stoppage, set-up, speed. defect/rework, which have been occurring in existing equipment.

MP Design: Main Functions

  • Capacity / Flexibility
  • Life Cycle Cost  / Life Cycle Profitability
  • Quality Assurance / Reliability / Skill level
  • Environment/people friendly
  • Fits with upstream/downstream processes

MP Design: Main Function Specification

Analyze needs reflected in the production of current products thoroughly before launching into design of new equipment

Set clear quantitative goals

–Quality

–Costs ( Initial / Running )

–Flexibility

  • volume
  • mix
  • new products

Draft specific plan for achieving these goals

–The work of designing equipment becomes the work of achieving a mission with specific goals

–Main function design

  • Quality Assurance design
  • Life Cycle Cost / Life Cycle Profit design
  • Flexibility design

MP Design: Main Functions

 

Capacity

  • throughput
  • balance between processes

 

Flexibility

  • volume
  • mix
  • complexity

Cost

IC (Initial Cost)

RC (Running Cost)

LCC, LCP

  • short-life products vs. long-depreciation change parts

Uncertainties

–volume

–mix

–complexities

  • Product life cycle

 

Quality Assurance

Technology / material selection

  • air-clutch/magnet-clutch/servo. for torque control

Reliability

Dynamic accuracy, tolerance

Reliable parts

Skill level required

  • mechanical  or servo drives

Design for Safety

  • Intrinsically safe

Reliability Design

  • Avoiding operation-stopping failures & operation-deteriorating failures

Operability Design

  • Ease of operation, changeovers & adjustments
  • Easy trouble shooting, preventing operation-error

‘Autonomous Maintenance’ Ability Design

  • Ease of daily maintenance

Maintainability Design

  • Ease of maintenance

‘Audit’ Design

  • Ease of predictive maintenance

MP Functions: Design Reviews

  • Prepare check lists for each MP function

ease of autonomous maintenance

ease of planned maintenance

ease of operation

ease of monitoring and data collection for kaizen

etc.

  • Study the MP information of existing equipment
  • Evaluate equipment specifications
  • Identify of apparent & possible problems
  • Revise the specification (if necessary)

MP Information

  • One-point lesson sheet
  • Current major losses
  • Trouble records
  • Maintenance records
  • Improvement records

MP function checklists ->

 

MP Function Checklist: Operability

Operators can do Operation & Changeovers quickly, accurately, and easily.

 

 

 

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