- Details
- Category: DAK Academy Support
The Break Out Road Map
The Break Out Roadmap is based on an analysis of successful countermeasures to breakdowns covering over 500 years of line running time. That analysis identifies 2 areas that contribute to 85% of the causes of breakdowns.
Fix these issues first to create the time and head space to progress from reactive to proactive maintenance.
Below is a summary of how to make that happen.
TPM Centre of Excellence Part 1
The breakout process involves stakeholders working together to surface and deal with the underpinning causes in a model area. This begins with the creation of a Centre of Excellence in a model area to:
- Develop an appreciation of the full range of issues to be addressed.
- Utilise the full knowledge and experience of the team to agree next steps
- Develop a deeper understanding of causal factors and collate lessons learned
- Test and refine potential solutions
- Implement and standardise new ways of working
- Lock in the gains.
The outcome is a deeper understanding of cause/effects and the development of countermeasures and standards which can then be transferred across the site.
Support Plan Structure
1: TAKE STOCK AND ENCOURAGE NEW THINKING.
- Readiness Review: Assess strengths, weaknesses, improvement potential and develop recommended next steps
- Plan the plan: Develop forward workplace learning projects
2: RAISE PERFORMANCE AND RELEASE POTENTIAL
- Training workshop: Asset Improvement Plan process to achieve standard speed
- Workplace Learning Project Scope:
- Define/confirm normal conditions and countermeasures to common problems
- Assess condition, identify and reduce accelerated wear
- Set and maintain basic equipment conditions
- Establish repair methods
- Organise routine production tasks
CHAPTER 3: BUILD CAPABILITY AND ENGAGEMENT
- Mid project review, policy development and forward planning
- Define critical control protocols
- Review/refine current control philosophy
- Standardise best practice routines.
4: DELIVER THE FULL POTENTIAL
- Capture lessons learned as Policy Standads and roll out to other areas.
Support Plan Example
Below is an example of DAK Academy support for practical improvement project around a troublesome asset. (Follow the links for more details of individual courses.)
A. Diagnostic Session:
Reliability for Manufacturing Leaders
Format: Remote/Online Session
This 2 hour on-line awareness workshop provides an insight into how award winning and well respected organisations are able to systematically deliver reliable, stable operations.
Learn how to counter the traditional pressures on output and break out of the reactive manufacturing environment where there is no time to deal with the root causes of unplanned downtime even when they are understood
B. Mobilisation Training Workshop:
Maintenance Planning, Scheduling and Work Control
Formats: In House training Workshop or Online
This training workshop provides a practical insight into best practice maintenance planning, scheduling and work control. That includes exercises to develop a customised pro-active maintenance planning approach as a driver for year on year improvement in maintenance effectiveness.
Learn how industry leading performers systematically progress from:
-
- Reactive ("fix-it-when-it-breaks") maintenance towards
- Predictive, productive asset management ("Stabilise and extend component life, predict when to fix-it-before-it-breaks and eliminate the causes of breakdowns").
C. Remote Implementation Support:
Drafting and Reviewing Asset Care Plans
Format: Remote/Online Training
This course provides participants with an understanding of best practice asset care principles and practical advice on how to achieve high levels of reliability. That includes the review of existing practices to understand and deal with the underpinning causes of problem hot spots.
Click on link for more information on Learning to improve Reliability
Take Control
Around half of breakdowns are due to lack of knowledge and skills of front line users.
Start with the work on problem assets to restore asset basic conditions and create basic condition standards. Use the process to develop front line team and team leader understanding and their capability to:
- Maintain basic conditions
- Collaborate with maintenance to
- Create a stable, organised approach to asset care.
- Develop trouble shooting algorithms for problem hot spots to systematically improve insight into cause effect mechanisms and improve inspection routines.
- Refine awareness and training plans to
- Embed visual standards within work routines so that they are easy to do right, difficult to do wrong and simple to learn
- Overcome knowledge and skill gaps.
- Assess competencies and assure high levels of cross shift compliance
The gains from dealing with these weaknesses are significant because applied to problem assets, they can become standards which are used to assure high levels of reliability for all assets.
The outcome includes the release of specialist and management time to focus on higher value activities.
Contact us for more information or to arrange a call to discuss how we can support your Breakout Reliability programme.
Get Better
Business Leader Development Modules
|
Who |
Task |
Learning Plan Content |
|
Business Sponsor, Support specialists, CI Manager |
Design, mobilise and manage the breakout programme Release and share knowledge and latent capability. |
Improvement principles, gap analysis, prioritisation and goal alignment, top down planning, organisation and control. |
Departmental Leader Development Modules
|
Who |
Task |
Learning Plan Content |
|
Departmental Head and Team Leaders |
Communicate the cause/effect linkages between effective maintenance and total costs Set and assess equipment condition standards |
Implementation roles and implementation route map and coaching to establish better working practices. |
|
Planners and Administrators |
Integrate the improvement activities as part of the routine work plan |
Asset plan development, improvement glide path definition, resource scheduling, tracking and capture of lessons learned. |
|
Engineering specialists and Trainers |
Define training needs by skill category (Not by asset) |
Standardise and systemise best practice to make it easy to do right, difficult to do wrong and simple to learn. |
Front Line Team Development Modules
|
Who |
Task |
Learning Plan Content |
|
Front Line Team Members |
Keep order in the workplace, reduce waste and non value added work. Track and deliver cross functional improvement goals. |
Select from the following modules |
|
F1 |
Stabilising asset performance |
Criticality analysis, establish condition standards and core asset care routines. |
|
F2 |
Setting asset improvement priorities/tactics |
Define trouble map, issue prioritisation and local asset improvement tactics. |
|
F4 |
Problem hot spot improvement |
Surface technology blind spots, systemise response and removal of causal factors. |
|
F5 |
Learning from sporadic losses |
Deal with accelerated wear and causes of human error |
|
F6 |
Problem observation and root cause analysis |
How to recognise patterns of failure and make "Normal conditions" visible to all. |
|
F7 |
Problem prevention |
Workplace organisation, best practice procedure design and implementation |
|
F8 |
Visual Management |
Visual management steps 1 to 4, Foolproofing and problem prevention |
|
F9 |
Targeting waste and hidden losses |
Use of OEE and Flow as leading indicators, understanding root causes and systematic improvement in waste and hidden losses reduction. |
