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Benchmarking Maintenance Performance: are you world-class?
A lean factory requires reliably running equipment and effective uptime control to operate at a world-class efficiency level. Every machine must be able to perform its task when required. To pursue ‘Zero Downtime’, potential breakdowns must be understood, effectively predicted, and addressed before they can occur. Regularly auditing Total Productive Maintenance (TPM) performance provides the necessary information to control uptime and improve Overall Operating Efficiency (OEE).
The Lean Maintenance Metric assesses how well equipment is maintained and uptime controlled. A lean factory requires reliably running equipment to pursue the ‘zero downtime’ breakthrough goal. The Leanmap Maintenance Checklist scores operating efficiency, effectiveness of maintenance organization, ratio between planned and unplanned stoppages, maintenance system approach, and method of uptime control. The Maintenance Checklist includes 5 points and takes 5 minutes to complete.
Downtime is expensive
Maintenance is a topic that does not receive much attention in traditionally operating companies, as long production is running reasonably well and shipments are on time. But as soon a critical machine breaks down, it becomes quickly clear that maintenance performance affects the entire value chain – with direct impact on flow, productivity, delivery, and bottom-line.
Efficiency demands Reliability
To protect processes from starvation and customers from missed deliveries, traditionally thinking managers often put costly inventory buffers in place to bridge the time the equipment is under repair. This approach addresses the symptoms, but not the causes. In contrast, lean thinkers are not willing to pay for unplanned downtime and the extra buffer inventory; they track maintenance performance and remove the root-causes of unplanned downtimes.
Key Success Factors to effective Maintenance
- All employees must be involved, not just technicians, engineers, and experts. Operators are responsible for routine maintenance, such as cleaning, lubricating, tightening, simple setups, inspection, and basic repairs.
- Maintenance activities and frequency are dynamic, not static. Schedules and checkpoints are adjusted relative to the age and condition of the equipment.
- Maintenance activities focus on the reduction of the six major productivity losses, not just one single dimension.
- Tracking downtimes by cause is a good starting point to analyze maintenance performance; review the following six productivity losses and create a Pareto chart of downtime causes.
The Six Productivity Losses
- Downtime – when equipment requires repair
- Changeover – when equipment is down for setup
- Minor stops – from uneven flow, checks, admin activities
- Speed losses – reduce speed to process low-grade material
- Scrap – non-conforming parts which cannot be repaired
- Rework – items processed more than ones
Scoring Total Productive Maintenance (TPM)
Lean thinkers want to know how well equipment is maintained and uptime controlled; they require a reliable assessment tool to score Total Productive Maintenance (TPM). To get a meaningful and accurate result, the assessment should cover overall operating efficiency, effectiveness of maintenance organization, ratio between planned and unplanned stoppages, maintenance system approach, method of event tracking, and effectiveness of uptime control.
Maintenance Check-1: Efficiency
How efficient is the operation? Are machines well-kept or run-down? Is downtime measured? Are the results charted and posted? Are operators satisfied with their machine performance? Is there a downtime goal set for each machine? Is maintenance performance linked to operating efficiency metric? Rate how efficient machines run.
Maintenance Check-2: Response
How is maintenance organized and performed? How many people are authorized to work on machines? Are they available when needed? Are operators qualified to perform basic maintenance? Rate how effectively maintenance is organized.
Maintenance Check-3: Stoppages
How many stoppages are planned, how many unplanned? Check downtime records. Planned stops are for maintenance, setups, and leveling. Unplanned stops are due to defects, delays, and disruptions. World-class operating performance means when virtually all maintenance events were planned for. Rate how many stoppages were planned versus unplanned.
Maintenance Check-4: System
Is there a process and system, such as TPM, to prevent downtimes through preventive maintenance? Is all equipment tagged and controlled? Are checkpoints and frequency well defined? Are maintenance plans defined and posted? Are they followed and up-to-date? Rate how effectively the system works to prevent downtimes.
Maintenance Check-5: Tracking
How is maintenance efficiency measured? Is performance continuously graphed, posted, and tracked to target? Are root-cause analysis completed for all downtime events? Are Pareto chart available, tracking downtimes by cause? Rate how effectively maintenance performance is tracked.
Audit maintenance performance now, it’s FREE and just takes 5 minutes to get your score relative to world-class TPM level.
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