time and motion study
 

Maintenance Management Resources
Six sigma and lean manufacturing, it's all about money:
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True Cost of downtime
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TDC - Data collection categories.     Add to favorites

 What you measure is what you’ll get!
 Ultimately must be able to accurately track failure rates and allocate costs
  •  individual machines (location, asset)
  •  machine categories (motors, pumps)
  •  components (bearings, seals)
  •  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) systems. 

    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 the enterprise.

    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

     

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