The unexpected stoppage of a equipment where a part is required or a repair over 10 min is required to restore machine functionality.
Seized cam replaced (25 min);
Suction cup replaced (5 min);
Broken cylinder replaced (35 min)
- Examples (Non-Breakdowns):
Guide rail adjusted (10 min)
Knife jam cleared (15 min)
Calibrate metal detector (5 min)
Reasons for Breakdowns
Breakdowns due to Forced Deterioration:
- A breakdown that occurs on any machine component/part due to lack of cleaning, inspection and lubrication
- Example: A cam follower that does not wear out evenly on its contact surface
Breakdowns due to Natural Deterioration:
- A breakdown that occurs on any machine component/part even though we are cleaning, lubricating or inspecting the machine properly.
- Example: a cam follower that wears out evenly in all the contact surface but is no longer capable to perform its function.
Breakdowns due to Out-of-Operating Conditions:
- A breakdown that occurs on any machine component/part due to the component/part being operated beyond its intended limits.
- Example: burnt glue particles clogging the filter or nozzle on the glue system due to operating the glue pot/hose at higher temperatures than the standard.
Breakdowns due to Lack of Knowledge:
- A breakdown that occurs on any machine component/part due to improper installation or repairs.
- Example: a chipped knife blade due to improper alignment of the stationary and moving knives during setup
Breakdowns due to Weak-point Part:
- A breakdown that occurs on any machine component/part due to poor design and/or fabrication on manufacturer’s part.
- Example: suction cup was breaking too often, reason – wall of suction cup too thin and weak to support load
Breakdowns & F-Tags
F-Tagging = Cleaning is Inspection: this activity is the heart of AM Step 1 activities.
It has one main objective:
Reduce breakdowns due to forced deterioration.
And two main activities:
- Identify abnormalities (through training by mechanics), and
- Fix abnormalities (through the F-Tag process)