- Details
- Category: DAK Academy Support
This support plan is designed to provide training and coaching support for those meeting the challenge of delivering zero breakdowns.
The training and coaching content provides a blend of Lean and TPM toolsets selected to develop internal capabilities using two business led support modules. These are:
- Breaking out of Reactive Maintenance
- Scaling up for growth. (to lock in the gains)
The precise programme will be developed to build on existing good practices and internal improvement capabilities.
Click on the above links for mode details of the conent of each module.
This includes guidance with the application of best practice to troublesome or critical assets to surface barriers/gaps to progress, deal with them and raise capabilities to:
- Improve Reliability and Effectiveness
- Engage front line teams with delivery of business goals
- Deal with knowledge and skill gaps
- Establish cross functional best practices
- Remove problem hot spots
- Reduce waste and increase capacity
As a result, in addition to business gains, the deliverables include experience of using cross functional team based workplace learning projects that engage production, engineering and support personnel with a shared improvement agenda.
Contact us to find out more about how a DAK Academy can support your journey to zero breakdowns and beyond
Planning the Programme
Research into effective Reliability countermeasures, based on analysis of over 500 years of line running time, identifies 2 areas that contribute to 85% of the causes of breakdowns. These are...
- Deterioration of equipment condition
- Human error
Understanding Causes of Deterioration
Accelerated deterioration, due to for example contamination or poor operating practices, is a significant factor in the premature failure of components.
The above research identified that reducing causes of accelerated wear stabilises and extends the life of around 80% of components. That makes their remaining lifespan more predictable which means that servicing of these components can be more easily triggered before a failure occurs.
Another major cause of accelerated wear is Human error. This is responsible for around 50% of component failures.
The factors that contribute to human error risk are:
- Unclear instruction,
- Complex working methods
- Lack of training.
Developing work routines that are easy to do right, difficult to do wrong and simple to learn not only reduces the likelihood of failure but also provide a vehicle to improve process precision, reduce defects, reduce energy waste and improve material yield.
To make that happen we can help you to:
- Define improvement glide paths to guide progress towards stable operation.
- Identify and remove the causes of accelerated wear and human error.
- Engage cross functional teams with removing skill and knowledge gaps.
- Develp skills to deliver best practice operation and asset care.
- Standardise work routines across shifts and work groups
- Simplify complex and difficult to complete work routines to reduce the risk of human error and prevent problems before they occur.
Find out how your organisation measures up to the practices of well known and award winning organisations by booking a 2 hour online in company Reliability Gap Analysis session for Manufacturing Leaders.
The content provides an insight for up to 8 delegates into how award winning and well respected organisations are able to systematically achieve reliable operations that deliver year on year improvement in performance.
Support Programme Overview
Support plans provide simultaneous training and coaching for Managers, Team Leaders, Key Personnel and front line improvement teams using a quarterly Workplace Learning cycle as set out below. :
Month 1: Mobilisation training including the assessment of potential improvement areas, prioritisation and development of improvement tactics.
Month2: Training and support coaching support for team sessions for the application of relevant focussed improvement toolsets.
Month 3: Feedback and transfer of lessons learned.
Training and Application Support
Workplace Learning projects provide immediate feedback on barriers to progress (real and imagined) which means that they can be used to help First Line Leaders to develop their ability to coach improvement teams as they:
- Set improvement priorities based on business performance drivers.
- Define improvement tactics and mobilise resources against a realistic and achievable timetable.
- Progress along that improvement path towards high performance teamwork capabilities.
- Enrol and engage those impacted with the change with the compelling need to adopt and refine the improved approach.
