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


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)

Define your Problem Statement.

The first step towards breaking your organizational log jams is identifying and verbalizing the challenge you're facing. What are you trying to solve? This simple Problem Statement exercise can have profound implications for your team. It helps you define the issue and gives TGG some sense of where the soft spots could be in your Order to Cash process. We invite you to take a few moments to fill out this form. A TGG consultant will contact you shortly to discuss your Problem Statement and provide some insight on how we may be able to help.

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