Journey to Excellence Building a Culture of World Class Asset Maintenance & Reliability Dale Deem CMRP- Reliability Engineer Oerlikon Fairfield Manufacturing February 21, 2018
Oerlikon Fairfield – Lafayette Largest Gear Manufacturing Facility in North America Page 2 Oerlikon Fairfield Confidential
Product Capabilities Extensive Capability for Custom Gear Manufacturing Specialty Gears and Shaft Components ü Spur, helical, bevel ü Internal, external ü Shafts over 3 M in length ü 20 mm to over 2 M Ø ü Finishing to AGMA 14 ü In-house heat treat capability
Quality is very important Do things right the first time • Even if you don't make a product you still need to work this way. Rework of any kind wastes time and resources. Scrap costs money and wastes time and often causes us to deliver late to our customers…. resulting in an unhappy customer.
How did we get to this point in time? 1. 2. 3. 4. A long standing tradition of “Can Do” attitude Dedicated and Mature Workforce A vast amount of Tribal Knowledge A diverse inventory of Equipment from Legacy to Latest technology
Opportunities for Improvement 1. 2. 3. 4. 5. 6. Most of the Assets are at least 7 or more years old Aged EAM System (AS 400) Inadequate PM Plans & Task Lists (or none at all) Inadequate or Missing BOM’s Maintenance Library is not well maintained No standardized Maintenance Work Flow “Squeaky wheel gets the oil” 7. Lack of Documentation
Oerlikon Guiding Documentation • *OP 4. 09. 3 Preventive Maintenance – Purpose – That suitable Preventive Maintenance is completed in a timely manner to ensure continuing Process Capability. – Scope – All Preventive Maintenance is performed on Production Machinery. * - OP = Operations Procedure
Guiding Documentation • ISO 9001 -2015 (Must Comply with by June 2018) – – – Section 6. 3 – Infrastructure Section 6. 3. 1 – Plant, Facility, and Equipment Planning Section 6. 3. 3 – Contingency Plans Section 7. 3. 1. 1 – Multidisciplinary Approach Section 7. 3. 3. 2 – Manufacturing process design output • Data Quality, Reliability, Maintainability, and Measurability – Section 7. 5. 1. 4 – Preventive and Predictive Maintenance • • • Planned Activities BOM Maintenance Plans & Task Lists
Guiding Documentation • ISO/TS 16949: 2009 (June 2018) – 3. 1. 7 – Predictive Maintenance – Activities based on process data aimed at the avoidance of maintenance problems by prediction of likely failure modes – 3. 1. 8 – Preventive Maintenance – Planned action to eliminate causes of equipment failure and unscheduled interruptions to production, as an output of the manufacturing process design – 8. 2. 3. 1 – Monitoring and measurement on manufacturing process • “…reaction plans when acceptance criteria are not met. Significant process events such as tool change or machine repair shall be recorded. ”
Where to Start • Begin with the end state in mind – What does good look like? – What is World Class? • What will it take to get there? – Resources • • Manpower Financial Facility Contractor • Accept that this is not a “Microwave” process rather a “Crock Pot Process”. The current state did not develop overnight
Develop a Comprehensive Plan • • • Methodical Detailed Milestones Do not press forward unless the preceding steps are in place Solicit support and “Buy in” Operations are your In-house Customer The end user is the Ultimate Customer The plan is an “Us” plan not “We vs. Them” Utilize Best Practice Data and Information (SMRP BOK)
Maintenance & Reliability Plan • Over simplify – – Make plan easy to understand Be prepared to explain as a process Remind yourself that this is something new to your facility Expect Pushback • • • Explain the features and benefits Explain the “What’s in this for me” to you audience Let’s Work Smarter, not Harder • Baby Steps – The journey of 1000 miles begins with one small step • Solicit support
Oerlikon Fairfield PM & Reliability Improvement Plan
Criticality Assessment
Finished Criticality Assessment
Research and Organize PM & Work Order History Remedy Statement Problem Statement
Work Order Level
Work Order Level Capture # Work Order Hours % of Hours Work Order Type
Machine Run Hour History We use machine run hours which are entered by operations personnel into AS 400 to determine when PM’s should be performed. Most Mazak equipment have a 1500 hour and 3000 hour PM
PM Task List
PM Task List
PM Task List
PM Task List Notes & Comments Use technicians notes for follow up work orders Also make updates to PM tasks
Pd. M Methodologies
Pd. M Methodologies Recommended action Impact Potential
Data Assimilation
PM Planning & Scheduling Meeting
PM Schedule Completed PM On Time PM Urgently Due (See Note) PM’s Upcoming and Scheduled in weekly PM planning Meeting
On the Horizon • • • Vibration Spectrum Analysis Reliability Awareness Training for Operations Storeroom KPI’s Inventory Optimization Real Time Asset Monitoring New EAM
Questions?
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