Equipment Reliability Concentration

Nearly everything that is done in service and manufacturing industries, is reliant upon equipment.  Rarely does that equipment ever run at top speed, making first rate quality products, for the entire time it is scheduled.  This week of train series introduces the students to basic metrics associated with understanding the health of equipment and how to improve its service level.

Prerequisites

  • Basic knowledge of electrical, mechanical, hydraulics, pneumatics and other equipment systems
  • Analytical problem solving
  • RCFA – Root Cause Failure Analysis  (useful, but not mandatory)

End results

  • Where to direct the team’s effort to produce more product with the same resources by understanding OEE data (Overall Equipment Effectiveness)
  • How to prioritize which equipment and systems to concentrate the maintenance team’s efforts upon
  • How to rationally determine a spare parts management plan
  • How to share responsibility between maintenance and operations (Autonomous Maintenance)
Training Agenda

Equipment Reliability

Concentration
2 weeks
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Data Analysis

Course
Week 1
  • (3) Root causes: lubrication, contamination, looseness
  • Collect the proper information to calculate Overall Equipment Effectiveness (OEE)
  • Use OEE data to evaluate, and improve equipment productivity, including the work order process
  • Estimate and use the Replacement Asset Value and determine when to apply asset management strategies
  • Estimate equipment’s Total Cost of Maintenance
  • Lubrication routes
  • Improve the reliability of plant air systems
  • OEE Waterfalls
  • Lubrication
  • Work Orders
  • CMMS
  • Plant Air
  • Capacity vs. OEE
  • Mapping downtime codes
  • Learning Simulation: TruckSIM
4 day

STRANDS Methodology

Course
Week 2
  • (7) Step STRANDS methodology by tgg
  • Total Productive Maintenance (TPM)
  • Reliability Centered Maintenance (RCM)
  • Equipment Reliability Road Map
  • Asset Certification
  • Critical Spares
  • Firefighters by trade
  • STRANDS team member roles
  • Build your own company STRANDS board template
  • Learning Simulation: TruckSIM Week 2
4 day

Define your Problem Statement.

The first step towards breaking your organizational log jams is identifying and verbalizing the challenge you're facing. What are you trying to solve? This simple Problem Statement exercise can have profound implications for your team. It helps you define the issue and gives TGG some sense of where the soft spots could be in your Order to Cash process. We invite you to take a few moments to fill out this form. A TGG consultant will contact you shortly to discuss your Problem Statement and provide some insight on how we may be able to help.

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