ZERO BREAKDOWN MAINTENANCE
One of any industry’s challenges is to achieve zero breakdowns in order to avoid re-works and stoppages of their production lines since they translate into extra costs. Maintenance focuses on providing reliable equipment capable of producing the perfect product. Product uptime is critical in many asset-intensive industries. Poor maintenance results in unplanned breakdowns, less than optimal performance, and costly repairs. Optimizing maintenance means minimizing the cost of maintenance while maximizing product uptime.
- Breakdown- when the loss of equipment’s functioning lasts for more than 15 minutes
- Failure or minor stoppage- when it lasts less than 15 minutes
Maintenance focuses on providing reliable equipment capable of producing the perfect product with Zero breakdown.
ZERO BREAKDOWN MAINTENANCE ACTIVITIES
Right Maintenance Strategies
System Prevent Costly Failures
Most importantly TMS Zero Breakdown approach helps in how to build into your maintenance system so zero equipment failure is a natural way that you run your operation.
Zero Breakdown Maintenance is built on three key premises :
- The first is that equipment will only work properly if its parts work properly. The better the condition of the parts, the better and longer the equipment will run.
- The second premise is that people use plants and equipment. The better the people interact with the plant and equipment, the better and longer the equipment will run.
- The third premise is that you are using the plant and equipment to build a business. The better the plant and equipment operate; the stronger and more competitive your business is.
MANUFACTURING EXCELLENCE IMPLEMENTATION PROCESS
Zero Breakdown: Maintenance is all about working for the ultimate goal with a winning maintenance strategy
- My Machine Campaign
- Machine Utilization Monitoring
- Machine Losses Reduction
- Breakdown Analysis
- Preventive Maintenance
- 3S ,4S & 5S for Machine & Office area
Employee Engagement: To improve workplace conditions that drive engagement and enhance employee sense of well being.
- Basic 5S Awareness
- 1S, 2S Implementation
- Workplace Visual Management (Visual Factory)
- Kaizen Strategy Implementation
- Suggestion Scheme
- Innovative Leaders
Zero Waste: To eliminate waste across entire waste value chains to the fullest extent possible through reuse and recycling. Zero Waste is more than just a problem of disposal but a need to reduce harm encompassing the entire life cycle of a product.
- Time & Motion Study
- Lean Layouting
- ZCA (Zero Cost Automation) & LCA (Low-Cost Automation)
- Material Handling Optimization
- OEE/ OLE
Zero Accident: The risk of falling, risks related to electricity or handling of machinery, road hazards, and more. Every day, the awareness of each and every employee is essential to avoid accidents in the workplace and to prevent occupational illnesses.
- OH & S Management System Implementation
- Safety KPIs
- Workplace & Safety
- Safety Signage Standardization
Zero Fatigue: Fatigue is a workplace hazard and can be associated with the safety and health of the worker. It affects the health and safety of the employee.
- Scope Defining
- Workplace Ergonomics Analysis different Technical Score (REBA, RULA, WAS, HARM, NIOSH, JSI, KIM, EAWS, RAMP)
- OFI(Opportunities of Improvements) Points Sharing
- Support in Workplace Design Modification
- Final Audit
Zero Effect: To make the production process, product, environment friendly and good enough for social well being and sustainability of the environment.
- Environment Policy
- Effect Impact Analysis & Life Cycle Assessment
- Energy Cost Optimisation
- Waste Management & Control
Zero Defect: Developing a product that has no defects but ensuring the quality standards and reducing the defects to a level of zero in your projects.
- Quality Management System Awareness
- Quality Performance (Quality KPI Development & Tracking )
- Non-Conformities Identification & CAPA Implementation
- Workplace Audit
- 7 QC Tools & 7 Management Tools
- Problem Solving & Poka Yoke
- Root Cause Analysis
Zero Loss: Zero Loss” is an aim/attempt to overcome such losses or minimize their effect up to great extent in order to reduce the manufacturing cost
- Advance Lean Practices Implementation
- Manpower Rationalization
- Design & Process FMEA
- Line Balancing
Zero Delivery / Failure: To accomplish the task within the lead time without failure in inventory time, WIP storage, logistics cost, and mapping of the steps a company takes to complete a certain process.
- Value Stream Mapping
- Value Supply Chain Management
- Inventory Analysis & Management
- Process Mapping (BPM/BPR)