Equipment Reliability Concentration

Summary

Nearly everything that is done in service and manufacturing industries, is reliant upon equipment.  Rarely does that equipment ever run at top speed, making first rate quality products, for the entire time it is scheduled.  This week of train series introduces the students to basic metrics associated with understanding the health of equipment and how to improve its service level.

Who are they?

People who focus on equipment reliability and help move the organization from reactive to planned activities within maintenance would benefit from this course. 

What is required?

  • Basic knowledge of electrical, mechanical, hydraulics, pneumatics and other equipment systems
  • Analytical problem solving
  • Root Cause Failure Analysis (RCFA) (useful, but not mandatory)

What types of problems can I solve with this toolset?

  • Where to direct the team’s effort to produce more product with the same resources by understanding OEE data (Overall Equipment Effectiveness)
  • How to prioritize which equipment and systems to concentrate the maintenance team’s efforts upon
  • How to rationally determine a spare parts management plan
  • How to share responsibility between maintenance and operations (Autonomous Maintenance)

 

Required Training Classes

Data & Transaction Training:

Equipment maintenance is one of the hidden jewels for Lean improvements. It involves not only the evolution from Corrective Maintenance to Preventive, Predictive, Autonomous or Quality Maintenance, but also the implementation of metrics and data analysis to determine when to repair or replace machines.

This in-depth training session offers the lean perspective towards equipment maintenance improvement. It recommends metrics to observe, their interpretation and how to manage work orders.

At the end of the session, participants will be able to:

  1. Collect the proper information to calculate Overall Equipment Effectiveness (OEE).
  2. Use OEE data to evaluate, predict and improve equipment productivity.
  3. Estimate and use the Replacement Asset Value and determine when to apply asset management strategies.
  4. Estimate equipment’s Total Cost of Maintenance
  5. Understand the impact of lubrication on asset life and maintenance cost, and concepts for how to improve your lubrication program.
  6. How to improve the reliability of plant air systems.

PDCA Improvement Training:

This course is designed for a learner with a full workload and limited resources. The goal of this training course is to give more time back to the learner, by teaching techniques that allow their teams to solve problems faster. What is your current asset strategy? How often is the organization challenged to choose between production or reliability? Preventing equipment failures is the goal. The good news is zero failures is possible. This course will cover the history of different generational approaches to reliability from the early 1930s to present day precision and predictive techniques.

In this course, you will learn proven methods to improve the health of your equipment, resulting in greater machine availability. The course will allow the learner to follow an equipment reliability strategy that introduces the following topics:

  1. Lean Manufacturing Principles
  2. Failure Prevention
  3. Total Productive Maintenance (TPM)
  4. Reliability Centered Maintenance (RCM)
  5. Equipment Reliability Road Map
  6. Asset Certification
  7. Critical Spares

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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