Maintenance Management Resources Six sigma and lean manufacturing, it's all about money:
Business Industrial Network is your best resource when you need fast solutions. After you view this six sigma area dedicated to learning the true cost of equipment downtime
with time and motion study, please visit our company.
Ultimately must be able to
accurately track failure rates and allocate costs
Major benefits can be attained
with current technology -- more effectively applied
lower cost data collectors
To accurately track cost...
How to select and implement CMMS software
Please check out this article - How to prioritize
production layout and categorize within CMMS. (The linked
CMMS article above donated by non-bias CMMS consultants - Perspective CMMS who
specialize in how to select and implement
CMMS software.) Note they did not overlook
plant wide bottlenecks like the powerhouse, steam, air, vacuum and emergency
power. After viewing the above article, you can use the back button to return
here and read the example below.
Some areas like Tooling often falls into the category “too small to analyze”,
even if MTBF is high. Once
you adapt TDC methods of
monitoring and analyzing downtime cost, you will be amazed at the potential
savings in what was once thought to be an insignificant category.
In the example of "Tooling", TDC shows us much larger categories
that add to the cost. When a tool breaks, it's not just a couple dollars to
replace, plus five minutes of time (labor). Each time a tool breaks or needs
replaced, there is cost of lost production (amplified by possible bottleneck),
scrap, quality, start-up cost, indirect labor (such as maintenance, quality,
engineering, supervisors, etc.). There is also risk of higher cost such as
Safety, damage to equipment etc.
After considering all the TDC
metrics outlined on this web site, it becomes apparent that ten cents you saved
on cheaper tooling could cost you hundreds or thousands times what the whole
tool cost. Especially when you are monitoring frequency of toll defect such as MTBF.
Ease of Data Collection and Analysis
As stated by John S. Mitchell and the MIMOSA
organization, your facility data must be readily available, easily exchanged and
clearly understandable for everyone with requirements throughout the enterprise.
Open exchange of equipment information between condition monitoring
(assessment), maintenance (CMMS)
and control (DCS)
Providing an open exchange of conventions will assure vital information to
define the status and condition of process, manufacturing and production
equipment is readily available and produces greatest value for users throughout
Require your vendors to adhere to MIMOSA standards of being capable of
automatic communication and (non proprietary or non specific) information
exchange. Software links can make system access of information, resident
in programs from different suppliers without special software.
Be aware of TDC and
MIMOSA categories, and insure they are in all your systems. To learn more about
these open standards, please right click on John S. Mitchell's power
point presentation to download. Also Please visit MIMOSA.org
Supporting the True Cost of Downtime with their product and services