Transcription
Daily Team Maintenance,Planned Maintenance, 5S
A Successful Performance System Includes:
Milliken Performance System
Daily Team Maintenanceand Planned MaintenanceThe 4 Phase Process
DTM and PM 4-Phase Approach
Is This Your Current Situation?Minor stopsBreakdownsSafety OEEYieldMorale
A dirty work environment istypical Machinery failures arenormal Accelerated deteriorationand abnormalities areexpected Operators “run” andtechnicians “fix”ConventionalThinking
Evolution of Key RolesOperator100Improvement,Small RepairsDaily Inspection50Transfer BasicMaintenance Skills50and TasksBasic Operation0Maintenance Techniques (FMEA, CBM)Maintenance SystemManagement% Time100% tenanceBreakdown Repairs0OperationBreakdown RepairsCare for EquipmentBreakdown Elimination
Integrated Model ApproachLeanManufacturingDecreasedMinor StopsDaily TeamMaintenanceEquipmentStabilityIntegrated asesand CostReductionsAreAchievable
DTM and PM 4-Phase ApproachPhase 1:ReduceBreakdownsPhase 2:LengthenEquipment LifePhase 3:ImplementPeriodicMaintenancePhase 4:PredictEquipment LifeDTMSteps 1-3DTMStep 4DTMStep 5DTMSteps 6-7PMSteps 1-2PMStep 3PMStep 4PMSteps 5-65SFocused ImprovementContinuous Skills Development
Daily Team MaintenanceWhat: DTM Provides operators with theknowledge and skills required toproactively prevent breakdowns and offquality caused by acceleratedequipment deterioration andabnormalities.Why: Targets losses due to minorstops, breakdowns, changeover timeWho: Cross functional teams ofOperators, technicians, maintenance,production leadershipWhere: Model Equipment first, thenall equipment plant wideHow: 7-Step process implementationPillar StepsDTM PillarTeamSAFETYDTMPMTeamFILeadQMPC7Team Leader 65SCSD75MMReplication MTeam 1EEMMCNPD0MMMM26MMMMM54Pillar Steps6TeamLeadReplication7Team 210M8M 8M810
7- Step Implementation Process
DTM Improved Our: eliminated dirt, contamination & deteriorationEquipmentPeopleCulture reduced breakdowns & downtime defined standards for optimal equipmentconditions educated operators on the identification &repair of abnormalities increased operator awareness and responsibility,& equipment knowledge freed up technicians to troubleshoot andredesign created an environment of pride, ownership,and responsibility eliminated the barrier between operators andtechnicians
DTM and PM 4-Phase ApproachPhase 1:ReduceBreakdownsPhase 2:LengthenEquipment LifePhase 3:ImplementPeriodicMaintenancePhase 4:PredictEquipment LifeDTMSteps 1-3DTMStep 4DTMStep 5DTMSteps 6-7PMSteps 1-2PMStep 3PMStep 4PMSteps 5-65SFocused ImprovementContinuous Skills Development
Planned Maintenance
PM Sub-PillarsDTM SupportSpare m intenanceMaintenanceCostManagementZero FailureActivities Zero breakdowns Improved reliability Improved maintenanceskills and capabilities Reduced maintenancespend
PM Improved Our:Maintenance Process established a predictive and preventative maintenance system& schedule developed metrics around maintenance provided methods to analyze and understand costEquipment Provided tools to analyze, track, and document machinefailures Eliminated root causes Implemented countermeasures to prevent recurrenceAssociates Provided education for technician (and operators) to raiseskills levels Assisted CSD pillar is DTM operator training
Roles: Operators vs MaintenanceOperatorsBeforeDTM/PM “I run it, you fix it!” inability/knowledge to detectand correct abnormalconditions fix breakdowns and minorstops when they occur “own” their machines maintain basic machineconditions: trouble-shoot major problems improve equipment bycorrecting design weaknesses assist teams in machinerestoration andcountermeasures provide technical support tooperators educate operators to: AfterDTM/PMTechnicianscleaning, tightening, lubricating identify deterioration identify abnormalities beforebreakdowns work with technicians to makeminor repairs participate in root causeanalysis develop skills/knowledge: machine function, minor repairsvisual inspection, properoperation cleantightenlubricateidentify abnormalitiesidentify deterioration
5S
How is it different?Ensures Associates have:What they needWhere they need itWhen they need it5S is not just housekeeping! to sustainablyeliminate inefficiencies
Questions?Jeff RosenlundDirector of Client EngagementPerformance Solutions by Milliken
5S PM DTM SAFETY Pillar Steps Pillar Steps. 7- Step Implementation Process. DTM Improved Our: eliminated dirt, contamination & deterioration reduced breakdowns & downtime defined standards for optimal equipment c
