Up Time Magazine- August/September 2008

to apply RCM methods to understand our most common failure modes, or our highest consequence failure modes, and then work with purchasing and accounting to make sure we had critical spares on hand. Using the Business Level FMEA to analyze a particular production system at the system level seems to work well in quantifying the opportunities and prioritizing them for further action. We need to understand the business consequence of each of the major failures in our business system, and then select the appropriate tool(s) or strategy to address these opportunities. the shop floor, getting them to help you in your observations as to specifically what is happening in the process and equipment. 4. It’s essential to look at your production system as just that, a complex system with many interactions. A good method for doing this analysis is the Business Level FMEA. Doing a Business Level FMEA should result in: • • • • Better teamwork Lower failure rates and downtime Improved output Lower operating costs Summarizing 1. It’s essential to look at the production process as a system, and fully understand the effects that the different areas within the system have on each other, and have within themselves. 2. It’s essential not to assume that you know where the biggest problem is until you’ve objectively evaluated the losses in each area and their respective interactions at the system level. Some of the data you have may lead you to the wrong conclusion. 3. It’s essential to “go and see” the problems at It’s essential that we view our manufacturing process as a highly complex and variable business system, and that we understand the failures in that system. Viewing anything that results in a loss of production capacity or extraordinary costs as a failure in our business system provides a good start for working as a team in quantifying those losses. Quantifying those losses and then applying the appropriate tools on a priority basis will minimize those failures, assuring the success of the business. However, the tools themselves are not sufficient. Management must provide continuous leadership for creating the environment that supports this approach - the time, tools, training, measures of success, and the sense of teamwork and common purpose needed. Management must align the organization to that purpose and follow up on the findings and action plans, assuring that they are done, measured, and rewarded on a continuous basis. These issues are major topics unto themselves, but for another article. Finally, it’s essential that we engage the entire workforce in improvement, not just a few focused on the biggest problems. If we don’t resolve the little problems, some of them will become big ones in the future. So, it takes a combination of efforts for world class performance. The business level FMEA helps us sort out the biggest problems, while we begin the process of engaging the entire workforce in solving the little ones. Summary When ABC began the process of reviewing the options for meeting an expanding market, its initial thoughts were to either borrow a tremendous amount of capital to build more plant capacity; or to buy a competitor, also an expensive proposition. After reviewing its current performance using the techniques described above, it concluded that it had adequate capacity in its current assets to meet demand for the next 3-4 years, if a “Best Practice” manufacturing process were implemented to maximize AFTER SETTING RECORD ATTENDANCE in 2007 with over 1,000 people, this year’s Annual Conference is sure to be the best yet. Session Tracks From the Five Pillars of the SMRP Body of Knowledge SMRP Initiatives Track Educational Workshops Exciting Keynote Speaker Comedic Entertainment Plant Tours Networking at the Rock-N-Roll Hall of Fame Golf Tournament DON’T MISS YOUR CHANCE TO ROCK OUT LARGEST AT THE YEAR’S MAINTENANCE & RELIABILITY EVENT. EXHIBITOR AND SPONSOR OPPORTUNITIES STILL AVAILABLE! REGISTER EARLY AND RECEIVE EARLY BIRD DISCOUNT Rock-n-Bowl Reception IT’S ALL TAKING PLACE OCTOBER 20-23, 2008 IN CLEVELAND, OH 20 16 august/september 2008

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Up Time Magazine- August/September 2008 Contents Upfront Upclose Information Technology Lubrication Infrared Maintenance Management Motor Testing Precision Maintenance Reliability Ultrasound Vibration Upgrade

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