Reliability Will Put your Competition to Rest
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This document discusses the benefits of implementing a world-class maintenance program to improve manufacturing operations. It notes that reactive maintenance costs U.S. manufacturers an estimated $750 billion annually. Having a world-class program can help reduce costs by taking a proactive approach rather than a reactive one. The document promotes the services of Visual Maintenance, which provides maintenance dashboard solutions, managed care programs, and custom plans to help manufacturers improve performance, reduce costs, and guide reliability efforts.
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Reliability Will Put your Competition to Rest
- 1. Creating a Company that would Put Yours out of Business! Visual Maintenance
- 2. Truths About U.S. Manufacturing! At this time there is an estimated loss of $750 Billion due to breakdown maintenance (reactive) or generally poor, incorrect or excessive practices.SMRP Solutions June 2010 If you are not a World Class Maintenance Organization… You won’t need to be - You’ll soon be Out of Business Being World Class Doesn’t cost you more Money! It actually cost you less!
- 3. SO WHY DOESN’T ALL MANUFACTURERS HAVE WORLD CLASS MAINTENANCE PROGRAMS?
- 4. SO WHY DON’T YOU HAVE A WORLD CLASS MAINTENANCE PROGRAMS?
- 5. Vision Command and Control Feedback Loop (Fire Fighting) Reactions to what gets your attention! Management Leadership Initiatives Control Feedback Third Party Resources Corporate Resources Value Execution Results Copyright © 2009 RightFoot Technology Inc. All Rights Reserved
- 6. Myth: Don’t have time to be proactive. But, what is the cost of being reactive? On Delivery! On Maintenance! On Quality! Impact On Profits! Competitiveness!
- 7. From my Vantage Point, You Don’t have time not to Be Proactive!
- 8. Is faster Better? Is “More” Better Just another Quick Fix The 4/5 Rule Myth: Faster is better! So how fast is fast enough?
- 9. From my Vantage Point, Slower is Faster!
- 10. Yesterday’s Value won’t make tomorrow's sales! We need a different context to win! With a Vision-2-Value Viewing Point You: See problem from a larger perspective Focus on the little things that make the big difference – Leverage Points Activities are accomplished with a goal centric point of view: Delivering: VALUE, VALUE, VALUE... Looking from a Different Viewing Point (Step 2 of Cultural Change)
- 11. Vision Corporate and Community Dashboard Command and Control Feedback Loop On-Course Correction Management Leadership Initiatives Control Feedback Third Party Resources Corporate Resources Value Execution Metrics Copyright © 2009 RightFoot Technology Inc. All Rights Reserved
- 12. Vision Corporate and Community Dashboard Command and Control Feedback Loop On-Course Correction Management Leadership Initiatives Control Feedback Third Party Resources Corporate Resources Value Execution Metrics Copyright © 2009 RightFoot Technology Inc. All Rights Reserved
- 13. Clarity Accountability Alignment - Balance Visual Maintenance is all About
- 14. What Does Your maintenance Program Look Like? RM BALANCE RM RM SM RM PM SM RM PM SM Reactive Maintenance Predictive Maintenance Scheduled Maintenance
- 15. Machine Optimization Optimized Performance for a Category of Machines A complete Plant Overhaul Targeted Custom Solutions Visual Maintenance SolutionsDelivering IMPROVED Performance on the Floor
- 18. Cost, Capacity and Threshold Management Dashboards Visual Maintenance Dashboards Maintenance Technician Contribution Dashboards Custom Dashboards Visual Maintenance SolutionsShow IMPROVED Performance Across the Organization
- 19. What We Do - SummaryWe Drive DOWN Costs! On-The-Floor Maintenance Solutions Managed Care Dashboard Solutions Goal Centric Driven Solutions Custom Dashboards to fit your specific Requirements Can Guide your Reliability Journey
- 20. Visual Maintenance is Results you can SEE!
- 21. Proper Maintenance is all about Balance
- 22. Scheduled Maintenance Over Time
- 23. Dashboard Demo Screen Shots
- 24. Proactive Maintenance Over Time
- 25. Reactive Maintenance Over Time
- 26. In Closing we would Like to Challenge each of you to… THINK From a Different Viewing Point! Because…
- 27. Today You are IN Business Tomorrow You could Be OUT of Business
- 28. Questions?
Editor's Notes
- Harvey:Visual Maintenance is Reality Maintenance On Steroids! – Barry Bonds at Bat Reality Maintenance + Dashboards Value Drive and Goal Centric Huck FinnLet see if we can create the company that would put your company out of Business
- Harvey: Is your company world Class?Is your company documented in the Book “Good to Great”Do you have and ISO or ANCI Certification? – Ticket to Play
- Harvey:Read SlideAsk Ron: A good Friend, and co-developer of Visual Maintenance to help answer this question. Ron McGary
- Ron: STAY AT THE WORLD CLASS LEVEL! Let answers go lower.By the end of discussion make sure you get something about:No time to be proactiveSpeed is During the discussion ask questions like: So how is that decision working out for you?...Also ask questions they can’t answer like: Is that causing your maintenance cost to go up or down?..I’ll record the answers on the board.
- Harvey:Describe diagram: Event Based Decision makingSMRP Solutions magazine stated that more than 60% of US manufacturing companies are TOTALLY reactiveMy experience says it is more like 80-80What could you do with 80% more resourcesTo Get Beyond this type of organization you must think differentlyLet me give you some examples:
- Harvey & Ron:Let me give you some real life examples that will de-bunk some of these myth!On Delivery – ACS 250 ends/day – Totally focused on results (Tunnel Vision) – Solution – Play the Bear GameRON: On Maintenance – On how Being Proactive changed the game in a reactive environment: Too many PMs, Not enough Inspections, Operator “I can”On Quality- Virtual Premise – Too busy to testResults: Profits (Down) Competitiveness (Room to be replaced)
- Harvey:How about you? Can anyone sight an example where being proactive became a game changer.No Answer, Ask: Does anyone ever check their tires on their car anymore? Why?Lets look at another Myth…
- Harvey:Fast is better is the kin to “More is Better <=Society way of thinking: More cars, bigger house…and second cousin to the “Quick Fix”. All of these type solutions lead to only one thing: More Breakdowns.Yesterday’s Quick Fix is tomorrow's problemAs a society => Would you say we are generally have a quick fix / faster is better mindset? What are some examples of that? Take a pill, left lane of 400How does that impact your workplace? Change a motor rather than fix the cause.A real life extreme example: Georgia Pacific Plant in Washington State and the 4/5 rule
- Harvey:Read the SlideHow about you? Can you tell of an example where slower if faster?I used these examples to help emphasize the point that if we are going to “Win”…We must start looking at things from a different viewing point…
- Harvey1: Re-State; Like the ACS Example2: Getting the right Trees: Truck Wash3: Asking why 7 times when fixing a machine, more than getting a paycheckTo “win” you have to change the structure of how the games being played – you need a different tool….
- Harvey
- HarveyA Vision-2-Value Visual Maintenance Program would look like this:Activities are not always based on events and reactive behaviorData RULES:Trend are Visible and managedIf large number of Techs: John does pump PMs 70% of the time. He would really like to learn more about mechanical problem solving but Jim is the company expert. Jerry, the Maintenance Supervisor would really like a backup for Jim who will soon be a new father. Jerry sits down with John a works out a plan that will increase the pump reliability index to 25 and reduce the pump reactive maintenance by 10%. Jerry also agrees to used the time savings to cross-train John as long as reactive maintenance on pumps does not increase.This is an example of using the Visual Maintenance Dashboard in a goal centric manner to change the structure of the game.Visual Maintenance is all about….
- Harvey:Visual Maintenance is all About:Clarity:What is being doneValue of EffortViewable to the right peopleAccountabilityContribution to the Corporate Vision – High LevelContinually ImprovingTech Contribution – Individual reliability indexesAlignmentScheduled Maint / Pms / Reactive Maint - BalanceProduction and Machine MaintenanceWhat get measures get improved, but it’s more than that it is about doing things the right way…Ron – Come up and talk a little more about Reliability Maintenance…
- RonQuote: Reliability Web.com Article: A Vision of Enterprise Reliability“Today, most organizations take shipping costs, plant efficiency, capacity constraints, etc. into account when leveraging the portfolio/fleet, but they do not consider the impact of reliability (or unreliability). Truly managing assets across the enterprise (including Reliability) will create game-changing results!”Stacks: RM 5 / SM 3 / PM 2 Final View: RM 3, SM 2, PM 2What does it take to get to the next level or even World Class?...
- Ron:Open with: What does it take to get to the next level?2. Assessments will drive the actions for a reliable solution or solutions either through line, machine, or component. 3. These assessment will drive their results in Two area: On the Floor Solutions and Managed Care Solutions. What are floor solutions? Pain, Improving Machine Up-time performance4. What are Managed Care Solutions? Delivering Data driven resultsLets look at the results of a machine optimization On the Floor solution…
- Ron:
- Ron:Now lets look at our Managed Care Solutions
- RonManaged Care solutionsA visual balanceof performance. How many of us have gone home without knowing whether we did a bad job or a good job at the end of the day?Unique Custom Solutions to fit your application.
- Ron1. Lets take a look at some of the dashboards
- Harvey:
- It would include a Dashboard that
- Harvey:
- Harvey:If time: Switzerland