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9 ways to achieve best practices in factory maintenance

Posted: 22 Jan 2015 ?? ?Print Version ?Bookmark and Share

Keywords:factory maintenance? best practices? production maintenance? OEMs?

It is possible to establish best practices in production maintenance, but to achieve this requires great effort from electronics original equipment manufacturers (OEMs). What makes this goal so difficult and why are manufacturers still running at a reactive model?

Many blame it on the age of their manufacturing assets and the repairs they require. More blame goes to not stocking the critical (and expensive) spares needed to sustain production. And still more can be blamed to today's fast-paced manufacturing that doesn't allow for proper planning or time management.

So what steps would be needed to reach world-class maintenance in this reactive environment? Here are nine easy steps to better maintenance practices.

Step 1

Step 1

The first step of any journey to best practices is to gather as much data as possible on machine downtime, meantime between failure, parts spend, tech utilisation, technician response time and percentage of deliveries made on time. With this, you can begin to calculate the average cost of one hour of downtime.

Step 2

Step 2

Given your estimate on the average cost of one hour of downtime you can then begin to monetise the effect of maintenance on production. By making some simple assumptions (based on the cost of one hour or downtime), how much would an improvement of only 5 per cent in machine availability be worth to your operation? Although it seems like a small amount, a 5 per cent improvement can provide remarkable results.

Step 3

Step 3

Now look through the variables in your operation. How much more savings would be possible by initiating a plan for critical spares? What effect would increased response time have on providing more machine availability? How would a work order system improve uptime?

Step 4

Step 4

As you analyse these variables you will start to see opportunities to add more value abound. Now it's time to invest. Adding a Computerised Maintenance Monitoring System (CMMS) will have a monumental effect on virtually all your variables. That's because a CMMS system will provide work order information; it will also increase technician response time which lowers your mean time to repair, which also reduces the amount of downtime.

Step 5

Step 5

Now that you are inputting work orders through the CMMS, every manufacturing asset in you operation is shown at the touch of a computer screen. Critical parts and spares can be tracked. Preventative maintenance (PMs) can be scheduled and checklists generated.


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