Maintenance Technology October 2016 - 12


PLANT PROFILE
sealing, and thermal-management technologies that improve
the efficiency and performance
of vehicles with conventional
and alternative-energy
powertrains. Dana serves three
primary markets-passenger
vehicle, commercial truck,
and off-highway equipment. It
provides the world's originalequipment manufacturers
and the aftermarket with local
product and service support
through a network of nearly 100
engineering, manufacturing, and
distribution facilities. Founded
in 1904 and based in Maumee,
OH, the company employs
more than 23,000 people in 25
countries on six continents.
There are more than 20 plants
and technical centers in the U.S.
The almost 1 million-sq.-ft. Fort
Wayne plant produces, among
other products, gear sets and
axle components, predominately
for light-vehicle markets, which
include passenger cars and light
trucks.

Dana's Maintenance Toolbox

Autonomous
maintenance program
McKenna has been the Fort
Wayne facility's maintenance
supervisor for three years. Jon
Weber has served 22 years as
the maintenance manager. They
agree that the heartbeat of their
86-member maintenance program
involves an autonomous atmosphere in
which the department is divided into
trades and led by team leaders.
"The team leaders who report to me
actually run the floor and the programs,"
McKenna explained. "In the mornings
we meet and determine a direction
of flow we want for the day. When
emergencies come up, I contact them
and they address the issue directly."
With more than 1,800 assets in the
Fort Wayne facility and about 150 PMs
issued each week, the maintenance
professionals stay busy, working three
shifts a day, seven days a week. Each
professional on the maintenance team
is responsible for a variety of machines,

12 |

MAINTENANCE TECHNOLOGY

■ Dana Operating Systems (DOS)-An in-house
system shared with all Dana manufacturing
plants that covers safety, processes, and
quality-control procedures.
■ eMaint CMMS System
■ Engineering group, consisting of 22 engineering professionals
■ Daily meetings to identify hot spots (priorities)
in the facility
■ Cell phones/text messaging provides a more
efficient way of communicating
■ Information and data compiled from CMMS
system and reports
■ Daily routines
■ Work-Order System-"Each one of our
operators and supervisors out on the floor,
whether they are production or engineers, can
write a work order," maintenance supervisor
Bob McKenna said. "That work order gets
sent directly to our maintenance people,
through specific printers in each department.
For example, if an electrician is needed, the
work order is sent directly to that supervisor's
printer in that department. This is a great tool
to know where to go, what to fix, and detailed
information about the problem."
■ Dell Roughneck computers for use on the
manufacturing floor
■ Infrared tools
■ Vibration-monitoring tools
■ Training videos, created in-house and
incorporated into the CMMS system
■ Four-Panel program.

including CNCs, conveyors, hoists,
fork trucks, electric-milling machines,
lift stations, double-lift stations, and
washers. They use electrical, mechanical,
multi-craft, mill, pipe-fitting, and
machine-repair groups.
The maintenance program combines
tried-and-true technology, some of
which is decades old, with new technology that incorporates the latest in
electronic control systems. In addition,
the company is dealing with scores
of upgrades each day. "A bolt is still a
bolt," McKenna said. "But all the drives,
robotics, and technical aspects of things
are changing rapidly. We have to stay on
top of both the old and the new."
The Fort Wayne facility has a robust

training program. For example,
nearly half of the electricians on
staff each have at least 30 years
of experience. An apprenticeship
program ensures that knowledge is
transferred to the next generation
of team members.
"In addition to the apprenticeship program, we have onboard
training whenever new equipment
is brought in," Weber said. "We
send the apprentices to work with
the machine builders for one or
more weeks of training. We want
people to specialize on specific
types of machines. We do a lot of
in-house training and some cross
training on different types of equipment and have some employees
who are specialists, for example,
with the cutting machines. We also
have precision grinding equipment
that requires specialized training."
Mechanical problems are more
common than electrical issues,
according to McKenna. "We often
will differentiate work orders
between mechanical and electrical.
We now have a lot of CNC
equipment, including vertical- and
horizontal-milling machines and
gear-cutting machines. These are
paramount to our operations."
Weber added that some of the new
equipment has diagnostic screens
that help electricians readily
identify problems.
"There is still a bit of equipment
in this facility that was installed in
1946 when the plant was built," Weber
explained. "Eventually, we will have to
replace some of these machines. But on
the mechanical side, we love some of
this old stuff. It is easy to repair and easy
to make parts for them and they were
definitely built to last a long time."

Using data to solve problems
Preventive maintenance has become
a priority. "We have seen some real
progress," Weber continued. "As we focus
on preventive maintenance, we can easily
see the number of emergency work
orders drop. We are focusing on keeping
the machines clean, taking the time
necessary to do the regular maintenance,
OCTOBER 2016



Table of Contents for the Digital Edition of Maintenance Technology October 2016

Maintenance Technology October 2016 - 1
Maintenance Technology October 2016 - Cover1
Maintenance Technology October 2016 - Cover2
Maintenance Technology October 2016 - 1
Maintenance Technology October 2016 - 2
Maintenance Technology October 2016 - 3
Maintenance Technology October 2016 - 4
Maintenance Technology October 2016 - 5
Maintenance Technology October 2016 - 6
Maintenance Technology October 2016 - 7
Maintenance Technology October 2016 - 8
Maintenance Technology October 2016 - 9
Maintenance Technology October 2016 - 10
Maintenance Technology October 2016 - 11
Maintenance Technology October 2016 - 12
Maintenance Technology October 2016 - 13
Maintenance Technology October 2016 - 14
Maintenance Technology October 2016 - 15
Maintenance Technology October 2016 - 16
Maintenance Technology October 2016 - 17
Maintenance Technology October 2016 - 18
Maintenance Technology October 2016 - 19
Maintenance Technology October 2016 - 20
Maintenance Technology October 2016 - 21
Maintenance Technology October 2016 - 22
Maintenance Technology October 2016 - 23
Maintenance Technology October 2016 - 24
Maintenance Technology October 2016 - 25
Maintenance Technology October 2016 - 26
Maintenance Technology October 2016 - 27
Maintenance Technology October 2016 - 28
Maintenance Technology October 2016 - 29
Maintenance Technology October 2016 - 30
Maintenance Technology October 2016 - 31
Maintenance Technology October 2016 - 32
Maintenance Technology October 2016 - 33
Maintenance Technology October 2016 - 34
Maintenance Technology October 2016 - 35
Maintenance Technology October 2016 - 36
Maintenance Technology October 2016 - 37
Maintenance Technology October 2016 - 38
Maintenance Technology October 2016 - 39
Maintenance Technology October 2016 - 40
Maintenance Technology October 2016 - 41
Maintenance Technology October 2016 - 42
Maintenance Technology October 2016 - 43
Maintenance Technology October 2016 - 44
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Maintenance Technology October 2016 - 46
Maintenance Technology October 2016 - 47
Maintenance Technology October 2016 - 48
Maintenance Technology October 2016 - Cover3
Maintenance Technology October 2016 - Cover4
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