Efficient Plant November 2017 - 19

feature | plant profile

Wood-grain-coated extrusions are finished.

do this on Monday because if we find an issue, vendors are open, suppliers are open, and we can get parts very quickly. We have other days for
scheduled maintenance on the other lines."
"Operations wants to reduce downtime and get more on the line,"
Joswiak continued. "Maintenance wants to make sure they have enough
time to take care of the PMs, but also in the event they catch something
and have to replace something, like a DC motor. Knowing that time is
always scheduled for downtime, it just works for scheduling. It works for
sales, operations, production, and maintenance. Even IT, for example,
knows they can do work on that line during that time."
Another major shutdown happens at the end of each year for major
repairs, equipment moves, and large projects.

THE RELIABILITY PUZZLE
The company's commitment to reliability is visible in many ways. The
scheduled downtime for PM goes hand-in-hand with the investment in
spare parts and purchasing new equipment when a permanent solution
dictates it.
"The difference from what we did previously is that we would find a
way to make a repair to put a Band-Aid on it in any way, shape, or form,
just to keep things running," Andreshak said. "We have evolved and
learned from that. We learned that if you had to use duct tape or rubber
bands to hold it together, then maybe it's better to just get it replaced.
This change in mindset is the most important change I've seen in my 32
years here."
According to Andreshak, another evolution is with the skill sets of the
workers. "Now we have automation and almost every piece of equipment is hooked up to PLCs. We now have robotics. So our facility looks
nothing like it did 30 years ago. We try to stay on the cutting edge, but
this requires additional training. We find ways to get creative. We have
forced our associates to think outside of the box. They need the basic

NOVEMBER 2017

skills-fabricating, designing, plumbing, and electrical-and we need
key people to do the programming for our automation."
Scheduling is a puzzle that must be put together each day so that
efficiency and reliability is always the result. In addition to the robust
maintenance program, this also requires engineering new processes and
technologies. Lannoye works closely with the maintenance team to train
and troubleshoot new equipment.
Lannoye always considers safety and ergonomics when making
improvements. For example, Linetec installed floor lifts, and air-flow
monitors, and replaced lighting. Reliability is at the core of all improvements and advancements. "For me, the reliability lies with my people,"
Andreshak said. "It is the whole group. If you can't count on the people
doing the task for you, then you are in a world of hurt." EP

Michelle Segrest is president of Navigate Content Inc.
and has been a professional journalist for 28 years. She
specializes in creating content for the processing industries and
has toured manufacturing facilities in 51 cities in six countries. If
your facility has an interesting reliability and/or efficiency, story
to tell, please contact her at michelle@navigatecontent.com.

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EFFICIENTPLANTMAG.COM |

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Table of Contents for the Digital Edition of Efficient Plant November 2017

Efficient Plant November 2017 - 1
Efficient Plant November 2017 - Cover1
Efficient Plant November 2017 - Cover2
Efficient Plant November 2017 - 1
Efficient Plant November 2017 - 2
Efficient Plant November 2017 - 3
Efficient Plant November 2017 - 4
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Efficient Plant November 2017 - Cover3
Efficient Plant November 2017 - Cover4
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http://www.nxtbook.com/atp/MaintenanceTechnology/mtapril2016
http://www.nxtbook.com/atp/MaintenanceTechnology/mtmarch2016
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