JR Dickens - IWCS 2007
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The document discusses reliability in asset management and maintenance. It defines reliability as machines producing quality output at design capacity for their lifetime. It discusses moving from reactive to proactive maintenance through a culture change. Key aspects are implementing preventive, predictive, and proactive maintenance approaches and using metrics to measure inputs and outputs. Case studies demonstrate benefits of condition monitoring to avoid breakdowns.
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This document provides an introduction to Overall Equipment Effectiveness (OEE), a methodology for measuring manufacturing productivity. OEE is calculated as the product of availability, performance, and quality percentages. World-class OEE is considered to be 85% or higher, achieved through availability of 90%, performance of 95%, and quality of 99.9%. The document discusses how to calculate OEE and its components, common loss events, and the importance of scrutinizing each component individually and together to improve productivity.
The Critical KPI to drive Manufacturing Productivity
A net reduction in cost of operations directly and positively affects the bottom line. Companies can boost revenue without sacrificing profitability by factoring in long-term debt-to capital ratio. Since finance puts a premium on a company’s ability to maximize productivity and use existing assets, you have to continually measure, analyze, and adjust your processes. This is accomplished by a rigorous practice of productivity gains, cost cutting with increased efficiencies, and maximizing returns on fixed assets.
OEE - The Critical KPI to Drive Manufacturing Productivity
An Introduction to Overall Equipment Effectiveness (OEE) - A Powerful Method to Improve Manufacturing Productivity
Lecture 1 - part 1.pptx
The document discusses various types of maintenance strategies including reactive, preventive, predictive, proactive, and reliability centered maintenance. Reactive maintenance involves fixing equipment only after it breaks down while preventive maintenance relies on routine inspections and servicing at pre-determined intervals. Predictive maintenance uses condition monitoring technologies to detect potential failures in advance. Proactive maintenance seeks to eliminate the root causes of failures to improve reliability. Reliability centered maintenance combines predictive and proactive approaches along with preventive maintenance and aims to optimize equipment performance and reduce downtime.
Maintenance management- Production Management
Maintenance management involves keeping production equipment in good operating condition on a daily basis. This includes maintaining existing plant and equipment, inspecting and lubricating machinery, and installing new equipment. The main goals of maintenance are to maximize equipment uptime and efficiency while minimizing repair costs and production downtime through activities like preventative maintenance, equipment inspections, and reliability engineering. An effective maintenance program requires planning work activities, scheduling tasks, and controlling costs.
Managing OEE o optimize factory performance
This chapter discusses measuring and optimizing factory performance through Overall Equipment Effectiveness (OEE). It begins by defining key terms like efficiency, effectiveness, and productivity. OEE is then introduced as a metric to measure equipment performance based on valuable operating time versus loading time. Losses that decrease effectiveness are categorized as downtime, speed, or quality issues. The chapter provides formulas to calculate OEE and analyzes how to implement OEE measurement systems and identify improvement opportunities.
The challenges facing in pharmaceutical maintenance
Maintenance strategies for the pharmaceutical industry.
Maintenance and service-related items are often the second-largest budget element in a laboratory after salaries and benefits
Presentation1.pptx
RCM is a structured approach that determines the most cost-effective maintenance task for every potential failure in an installation. It focuses on identifying proactive maintenance actions that reduce the probability and consequences of failures. The process involves analyzing failure modes, their operational impacts, and costs to determine optimal tasks like condition-based or time-based maintenance to avoid safety issues, production losses, and costs over time. RCM prioritizes safety and aims to cost-effectively maintain acceptable levels of system operability.
Rcm
Reliability Centered Maintenance (RCM) is a logical approach developed in the 1960s that helps companies improve equipment reliability by determining potential failure modes and maintenance plans. RCM analyzes a system's functions, potential failures, and failure effects to develop a maintenance plan. Implementing RCM increases maintenance effectiveness by ensuring the right type and frequency of maintenance, and increases efficiency by comparing maintenance costs to equipment downtime costs. RCM also provides benefits like upskilling maintenance technicians and operators through cross-training on equipment operation and failure analysis.
Capacity planning chapter 8
Capacity planning involves both long-term and short-term considerations. Long-term capacity planning relates to strategic issues like facility locations and technology. Short-term capacity planning concerns scheduling, labor shifts, and balancing resource capacities to efficiently handle unexpected demand changes. Critical capacity decisions involve determining optimal levels of raw materials, equipment, labor, storage and integrating these factors based on demand forecasts. Capacity is impacted by various interrelated factors and effective planning is needed to meet requirements at minimal cost while maintaining quality and competitiveness.
Implementing effective preventive and predictive maintenance programs
The document discusses implementing effective preventive and predictive maintenance programs. It covers various maintenance strategies including reactive, preventive, predictive, reliability-centered, and total productive maintenance. Key aspects of developing a preventive maintenance program are discussed such as performing a feasibility analysis, establishing time-based or dynamic-based schedules, and calculating overall equipment effectiveness. The document provides an overview of setting up an effective maintenance program.
Comparing RCM and PMO2000
The document describes a process called PM Optimisation (PMO) for improving maintenance programs. PMO aims to rationalize preventive maintenance tasks by identifying useless or duplicative tasks. It is a more efficient alternative to Reliability Centered Maintenance for mature assets. PMO involves compiling existing maintenance tasks, analyzing failure modes, evaluating consequences of failures, and determining optimized maintenance policies. Applying PMO can eliminate 40-60% of unnecessary tasks and improve asset performance and productivity.
Failure Modes and Effect Analysis (FMEA)
The ultimate guide on constructing a FMEA process for Manufacturing, Maintenance, Services and Design.
The presentation include step by step on how to determine the failure modes, failure effects, assign severity, assign occurrence, assign detection, calculate risk priority numbers and prioritize the RPNs for action. With some examples and illustrations.
Presentation contents:
1. Determing failure modes, effects and causes.
2. FMEA team & team leader.
3. Brainstorming.
4. The basic steps of FMEA.
5. Examples.
Where Does The Time Go?
This document discusses how tracking production downtime can help improve continuous improvement initiatives. It provides examples of using work sampling studies to identify sources of downtime at two manufacturing plants. This revealed significant unrecognized downtime and opportunities to increase uptime and capacity. Tracking downtime periodically provides visibility into improvement areas and can help focus continuous improvement efforts on issues with the biggest financial impact.
Maintenance
The document discusses various types of maintenance including preventive, corrective, condition-based, predictive, reliability-centered, and value driven maintenance. It explains that preventive maintenance involves maintaining equipment before failures occur to prevent downtime and costs, while corrective maintenance repairs equipment after failures. Condition-based maintenance uses indicators to determine when equipment will fail and prioritizes maintenance. Predictive techniques help determine equipment condition to schedule maintenance. Reliability-centered maintenance aims to improve cost-effectiveness and uptime. The 5S methodology focuses on effective workplace organization through sorting, setting in order, shining, standardizing, and sustaining these practices.
Similar to JR Dickens - IWCS 2007 (20)
The Critical KPI to Drive Manufacturing Productivity
The Critical KPI to Drive Manufacturing Productivity
The Critical KPI to drive Manufacturing Productivity
The Critical KPI to drive Manufacturing Productivity
OEE - The Critical KPI to Drive Manufacturing Productivity
OEE - The Critical KPI to Drive Manufacturing Productivity
The challenges facing in pharmaceutical maintenance
The challenges facing in pharmaceutical maintenance
Implementing effective preventive and predictive maintenance programs
Implementing effective preventive and predictive maintenance programs
JR Dickens - IWCS 2007
- 1. Reliability: Next Generation Asset Management James Robert Dickens, Ph.D. Temple-Inland Inc. Forest Products Group Diboll, Texas
- 15. Metrics
- 29. Case Studies
- 32. Conclusion
- 35. Appendix: The Economic Cost of Poor Reliability