Maintenance Management Resources Six sigma and lean manufacturing, it's all about money:
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with time and motion study, please visit our company.
These are "per downtime" occurrence entries, but most can be exported from your CMMS. Your existing method of reporting need only meet the TDC
Recording the actual time and other real time information associated with each downtime occurrence is crucial to the success of any maintenances goals. The work order is the apex to determining true downtime cost. You can do an excellent job of obtaining the constants of TDC equipment and labor categories, and still have bad downtime cost calculations due to inaccurate reporting of the actual downtime occurrence.
The fact is, there are still alot of facilities out there who do not utilize their work order system 100%. This problem is compounded by most systems not utilizing the information to it's maximum cost saving potential. This main category of "Downtime" covers these deficiencies..
Please click on sub-topic in yellow, to learn more.
Everyone records parts cost related to downtime occurrence, but did you include shipping cost? (them next day air often cost more than the part. :>)
Granted, procedures will need to be put in place and enforced to accurately
track downtime associated with equipment down, but the savings will be well
worth it. A common example to think about is one of production
"annoyance" classification. Although very seldom realized, there are
always production costs involved with these "annoyances".
In slightly more extreme cases, we have seen equipment failure resulting in
additional manpower go unreported and unknown to maintenance departments for
over 30 days. Clearly a breakdown in the management of the work order system. In
some cases, TDC shows the true cost to
production being 30 times the cost of the additional employees.
If the procedure and methodologies of TDC were in place, and cost was being indicated to all involved, the above example
could never occur. With all these categories, it may appear to be too much to
monitor and analyze. Click here to see why there is no need to sound the "Data