Leader Guide: Reducing Minor Stops and Defects

Beyond Zero Breakdowns

Even with stable operation, it is not uncommon for jams, fallen bottles and electrical trips to reduce the Mean Time Between Intervention (MTBI) for production operators to minutes.  Although plan achievement levels will be high, each minor stop reduces capacity, adds to energy costs and increases the risk of human error and quality defects.

By comparison, leading organisations have mean time between intervention measured in hours if not shifts.  In addition to freeing up time, that extends component life, improves material yield, reduces quality defects and saves energy. That also improves process resilience and the ability to flex output to match customer demand.  

Delivering these gains involves actions to sustain basic conditions with less effort, enhance problem detection and improve the quality of maintenance.