What is a Breakdown?

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The unexpected stoppage of a equipment where a part is required or a repair over 10 min is required to restore machine functionality.

  • Examples (Breakdowns):

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:

  1. Identify abnormalities (through training by mechanics), and
  2. Fix abnormalities (through the F-Tag process)

 

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