Equipment Reliability Assessment

What’s Included:

• New Equipment Design
• Management Metrics
• Maintenance Basics
• Developing Skill

New Equipment Design

• Whoever designed the new equipment obviously never had to service any equipment
• The repair parts are only identified by manufacturer part numbers
• Detailed maintenance manuals are:
  • Not available
  • Only in hard copy
  • Only in soft copy
  • Not specific to this particular machine
  • Not written in English (or Spanish, or French, or whatever language is needed)

Management Metrics

• OEE is better than world class but a considerable amount of scrap is generated
• There are three different versions of unplanned downtime depending upon which report you look at
• Operators don’t know what OEE means or how they might affect it
• A lot of money is spent on maintaining old equipment but, we aren’t sure if the spend is justified
• No one knows what an hour of lost production is worth

Maintenance Basics

• Only the mechanics can work on the machines
• No one knows if there is supposed to be fluid in a chamber of the FRL
• Purchasing got a good deal on lube oil but didn’t ask maintenance for the design specs
• The maintenance team is scheduled to work 6 ½ days per week, every week

Developing Skill

• A lot of knowledge is going to walk out the door when the old guys retire
• We are too busy to conduct any evaluations after the equipment is up and running again
• Planned maintenance always takes longer than expected

Outcomes:

A prioritized action plan for how to improve equipment OEE which may include:

• Adjusting critical spares carried in inventory
• Improving lubrication practices
• Changes to plant air systems
• Better planning for maintenance events
• How to improve the skill set of those performing maintenance (both maintenance team and operators)