- Details
- Category: Support Plans
Reliability Learning Club support plans provide cross functional project teams with a structured awareness and coaching programme to develop a deep collective understanding of the issues involved in delivering zero breakdowns. The programme begins with a diagnostic of current practices against best in class benchmarks.
That is used to align team outlook about gaps and priorities and mobilise practical projects to both deal with the gaps and raise capabilities. This is supported by coaching plans at an individual and team level as required.
Few of the problems which impact on Reliability can be resolved by purely technical improvements.
The challenging but achievable LeanTPM goal of Zero Breakdowns requires as much attention to collaboration, problem ownership and learning as it does to the use of analysis tools and techniques. Not something that can be taught in the classroom.
The Reliability Learning Club provides training and coaching to develop in house capability to:
- Diagnose gaps and barriers that constrain progress
- Systematically improve Reliability and Effectiveness
- Engage front line teams with delivery of business goals
- Analyse production assets to develop a deeper understanding of correct operation and asset care
- Deal with knowledge and skill gaps
- Develop and disseminate best practice across functional boundaries.
- Assure learning and compliance processes
- Identify and prioritise problem hot spots
- Enhance and improve the use of underpinning systems
- Reduce waste and increase capacity
That also provides a template for practical, cross functional team based projects that engage production, engineering and support personnel with a shared improvement agenda. An approach that makes every day a learning day
Contact us to find out more about how a DAK Academy Learning Club can aid your teams journey to zero breakdowns
Taming Technology for Good!
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. We call this activity Problem Prevention.
Implementing the countermeasures to accelerated wear and human error involved the enhancement of 6 shop floor processes. These are:
- Asset specific focussed improvement glide paths to track progress towards stable operation.
- The systematic removal of causes of accelerated wear and human error.
- Cross functional team engagement with removing skill and knowledge gaps
- Skill development of best practice operation and asset care capabilities
- Standardisation of work routines to assure consistency of working methods across shifts and work groups
- Simplification of 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 against 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.
