Module 3 : Asset care and equipment effectiveness
Optimising equipment effectiveness is a high priority in all world class organisations. Teamwork between maintenance staff and operators is essential for the achievement of high levels of equipment effectiveness.
The goal of Equipment Optimisation is to increase availability (in other words, eliminate breakdowns and reduce changeover times) and have equipment producing quality products at full speed.
How operators can help to improve equipment effectiveness
The operators of machines can best control a number of factors that impact on Availability, Speed and Quality (ASQ). Mission-directed team leaders need to fully understand these factors, so they can coach their team members and involve them in improvement.
The five main areas where operators can help to improve equipment effectiveness are:
- Equipment cleaning. Cleaning equipment improves Availability, Speed and Quality effectiveness by eliminating dirt and grime build-up and by identifying potential problems which could affect ASQ.
- Lubrication. If equipment is not adequately lubricated, breakdown and rapid deterioration will be the result.
- Daily checksheets. The completion of daily checksheets to ensure that equipment is in good condition is a common practice in world class companies. When problems are identified, they are rectified timeously. A maintenance management system must be in place to ensure that timely action is taken.
- Correct equipment operation. When equipment is misused, ASQ will be impacted. Standard operation procedures for start-up, shut-down and actual operation are essential for training operators and ensuring that equipment is used correctly in a consistent manner.
- Quick changeover. If changeovers occur often, are disorganised and take a long time, ASQ will deteriorate. The solution lies in involving the team to develop methods that can reduce changeover times to less than 10 minutes and then adopt well-planned standard methods.
As a company progresses towards world-class status, maintenance staff spend less of their time reacting to breakdowns and more of their time focusing on Preventative Maintenance (PM) and maintenance planning (such as ensuring spares and exchange parts are available). When your maintenance staff is spending less time on breakdowns, they can start focusing on new key responsibilities, such as the following:
- Developing PM systems and carrying out PM;
- Conducting regular inspections for important equipment;
- Participating in joint problem solving teams involving operators;
- Training operators in the use and functioning of equipment;
- Involving operators in co-ordinating improvement maintenance;
- Helping teams to achieve single minute changeover.
One of the key focus areas of Competitive Dynamics Internationalâ€™s Mission-Directed Work TeamsÂ® programme is to help your company become a world-class organisation by improving overall equipment effectiveness (Availability, Performance and Quality) by identifying, prioritising and eliminating losses. Contact CDI to find out more about the Mission-Directed Work Teams.