Early Equipment Management Workshop

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

Early Equipment Management Goals

Design production equipment that 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 have worn after the 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 the 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 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
- elimination of 16 Major Losses (occurred, existing, possible)
Effective feedback of operational knowledge
- communication between equipment designer and operators/maintenance staff
- equipment 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

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 has 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 the design of new equipment

Set clear quantitative goals

Quality
Costs ( Initial / Running )
Flexibility
- volume
- mix
- new products

Draft a 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