Maintenance Technology July 2015 - (Page 6)

UPTIME PDCA Drives Parts Management Bob Williamson Contributing Editor L earning about maintenance excellence and deploying maintenance best practices are among our top goals in the quest for equipment- and process-reliability improvement. But there is a huge gap-let's call it a chasm- between learning and deploying. We can learn much from those who have preceded us. I recently attended the annual meeting of the Maintenance Excellence Roundtable (MER), hosted by Syngenta, a Switzerland-based agrichemical firm, in St. Gabriel, LA. The MER is an invitation-only group of plant maintenance and reliability leaders whose facilities have demonstrated exceptional, Use of the PDCA/scientific method system by the Storeroom Materials Management Team at Syngenta's St. Gabriel, LA, facility resulted in a major upgrade in performance. and more in-depth probing of these first-hand experiences, an invaluable takeaway for participants. This month, I'll share one of the presentations that demonstrated maintenance best-practice deployment with a strategic focus. Best-practice deployment How do we decide where and how to improve maintenance: through a best-practices implementation project, a strategically focused deployment, or both? Unfortunately, maintenance best-practices deployments often turn into long-term maintenanceimprovement programs. In these cases, it's not unusual for the program to rely on a single person to set the pace and maintain progress. This leader often must struggle to become a sustainable part of the organization's culture while attempting to address specific business goals. By contrast, a strategically focused deployment of maintenance best practices can assure that improvement efforts are aligned with business goals. Results of these efforts can be measured and quantified, and linked to specific measurable business-related indicators. The key is ownership, learning to follow a change process, and then changing old habits along the way. Using this method, sustainable results can be quickly achieved. PDCA and the scientific method sustained performance in maintenance best practices and improved reliability. The group was formed in the 1990s to help member companies learn from each other's experiences. Each year a different member company hosts the annual meeting, which includes presentations from each member company and plant tours that highlight maintenance best practices in action. This year's event featured presentations from Syngenta Crop Protection, Honeywell, Aera Energy, FMC, 3M, DuPont, and Johnsonville Sausage. Each was designed to share specific insights from their maintenance and reliability improvement journeys. The group is small enough to allow discussion 6| MAINTENANCE TECHNOLOGY Students of the Total Quality movement from the 1980s or the lean tools that followed will recall Dr. W. Edwards Deming's continuous-improvement cycle of Plan, Do, Check, Act (PDCA), based on the scientific method. Deming's teaching in Japan after World War II led to the modern quality-control movement that emphasizes the scientific method. This PDCA/scientific-method process was noted as the foundation of the Toyota Production System, Total Productive Maintenance, and Six-Sigma Quality. Variations have included PDSA (study) and PDCA (adjust). One of the MER presentations featured Syngenta's use of the PDCA/scientific method for improving storeroom performance. However, their process didn't start with PDCA. It began by forming and JULY 2015

Table of Contents for the Digital Edition of Maintenance Technology July 2015

Forward Observations
For On The Floor
Drive Strategy With Performance Metrics
Train, Audit Electrical Workers
Carbon-Neutral Drives Molding Company
Troubleshoot Hot Hydraulics
Lubrication Strategies
Don't Procrastinate, Innovate
Ad Index

Maintenance Technology July 2015