Improving Processes and Focusing on Value
Joe Mikes, Sr. Consultant, Life Cycle Engineering
As appeared in the May – June 2007 issue of Reliable Plant
Improving upon maintenance processes has become a fundamental part of running a business for maintenance managers. Multiple mini-process tools have been developed to help managers uncover poor processes performed in plants; such as Follow the Baby – Observing a work order from birth to maturity, or DILO studies – “Day in the Life Of.” The real question is what should be done with the information once it has been gathered? You will find that the answers are unique to each industry; however, the methods for utilizing this information are universal.
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Toyota Improvement Model
1. Overproduction, typically using machines faster than necessary as long as they have any parts to process.
2. Waiting for a machine to complete an automatic cycle or for parts to arrive.
3. Unnecessary transportation relocating parts at any time in the process
4. Processing itself, reduce or eliminate any non-value added steps within the process.
5. Inventory on hand beyond any need to support normal operations.
6. Movement unnecessary searching, reaching, carrying, or positioning parts.
7. Defects, producing out-of-spec goods.
Although the application of the seven wastes was designed for the operations/production section of the manufacturing plant, the principles remain valid for maintenance activities. An adjusted list, which includes the maintenance activities, of definitions may look like this:
1. Overproduction, rebuilding 5 electric motors despite the need for only 1.
2. Waiting for a machine to become available to PM.
3. Unnecessary transportation or reducing trips to the store room.
4. Processing itself, conducting PMs when they are not needed
5. Inventory, bringing 6 lengths of pipe jacketing to a job when you only need 2.
6. Movement, leaving the hand tools on the ground when the job is up on a mezzanine and climbing back and forth.
7. Defects, accepting temporary repairs, or causing additional errors while executing a PM.
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