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Your Partner in Condition Monitoring

This document discusses strategies for improving manufacturing performance through effective maintenance practices. It outlines how moving from reactive corrective maintenance to proactive condition-based maintenance can improve availability, efficiency, quality rates and overall equipment effectiveness. Adopting world-class maintenance strategies focused on prevention, continuous improvement and optimizing uptime can boost profits by reducing downtime, quality losses, energy waste and capital expenses while enhancing workplace safety, flexibility and the environment.

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65 views

Your Partner in Condition Monitoring

This document discusses strategies for improving manufacturing performance through effective maintenance practices. It outlines how moving from reactive corrective maintenance to proactive condition-based maintenance can improve availability, efficiency, quality rates and overall equipment effectiveness. Adopting world-class maintenance strategies focused on prevention, continuous improvement and optimizing uptime can boost profits by reducing downtime, quality losses, energy waste and capital expenses while enhancing workplace safety, flexibility and the environment.

Uploaded by

Anonymous ffje1rpa
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPSX, PDF, TXT or read online on Scribd
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Your partner in condition monitoring.

World Class Manufacturing


[is for free]

Trend in industry
Larger units, less people

Availability
Time factor
Downtime

Production time Available time

Available time Total downtime Available time

= Time factor

Performance efficiency
Speed factor
Performance efficiency (speed, ton/hour) 100 %

Time
1 1 = Speed losses at start of the production 2 = Speed losses at stop of the production It's possible to minimize losses by avoiding unscheduled downtime. 2

Quality rate
Quality factor
Quality rate 100 %

Time 1 2

Loss of contribution
Overall Performance Effectiveness
Availability
100 h 90 h
A = 0.9 (time factor)

Performance effectiveness
90 ton/h 81 ton/h P = 0.9 (speed factor)

Quality rate
81 ton 73 ton

Q = 0.9 (quality factor)

OPE = 0.9 x 0.9 x 0.9 = 0.73 x 100 = 73% World Class Performance >85%.

Maintenance
Corrective Maintenance Unplanned (unpredictable break down)
Planned (predictable) Objective With Instruments Preventive Maintenance Indirect PM Condition Monitoring Direct PM * Lubrication * Cleaning * Fixed Time Replacement Improvement Maintenance Design out Life Time Extension

Subjective With Human Senses


8

Strategies

BREAK DOWN MAINTENANCE

FIXED TIME MAINTENANCE

CONDITION BASED MAINTENANCE

DESIGN OUT MAINTENANCE


9

Maintenance Strategy
Reliability
100% 80%

60%
40% 20% 0% Pumps Fans Chillers

Corrective Time based CBM

P/PM Technology, Feb. 2001

10

How do we spend the time


90 80 70 60 50 40 30 20 10 0 Traditional World Class

Wrench time Think Improvements

11

Maintenance costs
The ants view

Direct maintenance costs:

Wages and salaries Material costs Administration costs Costs for training Spare part costs Contracted work forces Modification costs

12

The eagles view

Break the tunnel vision

13

The hidden possibility

MAINTENANCE

QUALITY LOSSES

ENERGY LOSSES CAPACITY LOSSES

CAPITAL COSTS

WORK ENVIRONMENT INCREASED INVESTMENTS LOST MARKET

PRODUCTION LOSSES

14

Company culture
Company Work Hard

Company Work Smart

15

16

17

Work hard

Work smart

30%

20% 5%

10%

5% 80%

10% 40%

Availability loss OEE Quality loss Performance loss

18

Customer perspective

Delivery

time

Quality Price Brand name

19

Employees

Safety

Work environment Stress Sick leave Overtime Image

20

Environment

Polution Waste Energy consumption

21

Owners

Profit Capital investment Product output Quality Flexibility of changes in production Incidents Maintenance costs
22

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