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Journey to Excellence Building a Culture of World Class Asset Maintenance & Reliability Dale 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 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 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 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 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 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 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) – – 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 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 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 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 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 Oerlikon Fairfield PM & Reliability Improvement Plan

Criticality Assessment Criticality Assessment

Finished Criticality Assessment Finished Criticality Assessment

Research and Organize PM & Work Order History Remedy Statement Problem Statement Research and Organize PM & Work Order History Remedy Statement Problem Statement

Work Order Level Work Order Level

Work Order Level Capture # Work Order Hours % of Hours Work Order Type 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 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

PM Task List PM Task List

PM Task List Notes & Comments Use technicians notes for follow up work orders 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

Pd. M Methodologies Recommended action Impact Potential Pd. M Methodologies Recommended action Impact Potential

Data Assimilation Data Assimilation

PM Planning & Scheduling Meeting PM Planning & Scheduling Meeting

PM Schedule Completed PM On Time PM Urgently Due (See Note) PM’s Upcoming and 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 On the Horizon • • • Vibration Spectrum Analysis Reliability Awareness Training for Operations Storeroom KPI’s Inventory Optimization Real Time Asset Monitoring New EAM

Questions? Questions?