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.
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:
The outcome is a deeper understanding of cause/effects and the development of countermeasures and standards which can then be transferred across the site.
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:
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
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:
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.
|
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. |
|
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. |
