7 Steps Approach To Reduction Of Unplanned Breakdown

Introduction

Equipment breakdowns are usually very expensive to fix and also result in substantial opportunity costs due to equipment/ facility downtime. A proactive planned maintenance program can be very effective in reducing such unplanned breakdowns. Moreover it will also ensure a larger life cycle of your machines. So the gain is in reducing costs as well as increase in productivity.

Many deferent kinds of related problems can arise with the equipment, machines, and installations on the factory floor:

Unplanned minor stoppages (3 minutes or less) that disrupt production.

Unplanned medium stoppages (4 to 30 minutes) and Major stoppages (more than 30 minutes) that halt production.

Waste from stoppages for Pre-setup, parts replacement, or maladjustments during setup and changeover

Stoppages to replace tooling

Waste from rework, defects, or poor yield

Waste from machines and equipment standing idle due to shortage of parts

Waste from lines disrupted by employee absences.

These 7 types of wastes are all important, but from the view point of maintenance, the most important kind of waste is defects due to equipment problems. This training is about finding ways to eliminate these wastes quickly and reduce the unplanned breakdown

 How Will You Benefit

• Developing techniques of Current Condition Study
• Line Problem Summary
• Analyzing Minor Stoppages Mechanisms and Their Causes
• Forming Clear Picture of Phenomenon, Mechanisms, and Causes
• Setting up an Instant Maintenance System
• Providing Support for Autonomous Maintenance Activities
• Creating Instant Maintenance Manuals and Demonstration Techniques to Achieve Three Minutes or Less (world-class standard) Recovery Time of Equipment Stoppages

Who Should Attend

This course is suitable for all personnel that are responsible to solve operational issues and response to (internal & external) customer complaints,

• Maintenance Manager, Engineers and Senior Technicians
• Engineering Managers, Engineers and Executives.
• Industrial/Process Managers and Engineers
• R & D Managers, Engineers and Executives
• Any Non-technical Personal who because of the nature of work, are involved or are interested to more about modern equipment maintenance.

Methodology

For each of the topic covered, the participants are introduced with fundamental concepts and immediately follow-up with related learning activity to facilitate learning. In such, participants are required to perform the tasks through group activity discussion and analysis in a work-relate simulated situation to demonstrate the learning topic outcome.

Module