Developing Skills to Reduce Minor Stops and Defects

Planning the Programme

As the causes of failures are dealt with, Reliability improves and unplanned downtime is less common, downtime becomes less useful as a basis for setting improvement goals. Ratcheting up performance involves a transition in outlook from preventing downtime to preventing defects. This transition has significant impact on Daily Management Routines for Managers, Front Line Leaders, Engineers, Planners and Support Functions. Instead of reacting to problems as they occur, their daily routine adopts a focus on releasing the full potential of assets that are running but could do more. 

The gains include:

• Reduced contamination and extended component life
• Improved material yield
• Improved process precision and quality assurance
• Improved equipment condition and simplified operating and asset care practices to first stabilise and then optimise technology performance;

The impact on work routines are:

• Increased time between interventions for production, hygiene, engineering and quality. This makes it possible to delegate more of the routine to front line teams;
• The option of running additional shifts with minimal labour cover;
• Shorter order lead times and reduced inventories. Naturally to take advantage of that involves changes to order processing cycles and Quality Assurance protocols.
• The release of maintenance engineering time from routine activities to focus on long term solutions to technology problems;
• This doubles the value to the organisation of traditional maintenance engineering role and puts the maintenance function at the heart of Lean improvement process;
• The systematic development of front line team self management capability including routine work planning and coordination.

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