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2013 SEPTEMBER ISSUE
Lean Maintenance Reducing waste and cost
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In the news
Lean maintenance Reducing waste and costs Lean maintenance programmes focus on driving efficiencies within the asset management and maintenance areas of manufacturing operations. As with all lean activities it is a journey and not a destination - the continuous improvement of an evolving process. Toyota, who have been applying lean for over 95 years continue to focus on lean maintenance as a priority as they recognise its impact on the smooth flow of operational lines. Lean maintenance is often referred to as Total Preventative or Total Predictive maintenance. Many organisations that have been implementing Lean for decades are only now giving maintenance the attention it deserves. Those new to the adoption of lean should mark it as a top priority. Efficient maintenance programmes can drive significant improvements to productivity and process improvements, resource efficiencies and importantly significant financial benefits.
Step 1 Apply organisation to the work areas Utilising Five S principles within the maintenance area will provide a sound basis for identifying value and waste within the maintenance process.
Step 2 Identify Value Streams and Strategy Maps Understanding the value streams will help you identify which activities add value and which do not and can therefore be removed. Strategy maps map the lean activities with the companies overall strategic goals.
Step 3 Optimise Planning Implementing and utilising maintenance good planning and project management will drive significant efficiencies and improvements within maintenance activities
Step 4
Advanced Technology Services provide maintenance solutions to the world’s largest manufacturers such as Caterpillar, Eaton, Honeywell, Dell and Ford. They have identified ten critical steps for implementing
Prioritise, repair and refurbish
a successful lean maintenance programme
to a good standard and then maintain it.
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In applying lean maintenance you are looking to reduce waste, cost and improve productivity. To achieve this it is important to get both plant and maintenance equipment
Step 5
Step 8
Implement predictive strategies
Employ the tools of Six Sigma
Predictive maintenance provides a forecast
Most organisations will use a computerised
schedule of planned maintenance activity
maintenance management software (CMMS)
based on historic data. Predictive strategies
which can be used for preliminary six sigma
deliver considerable cost savings and
evaluation. Once useful data is gathered
improve asset longevity and they are
within the CMMS tracking failure causation,
shown to significantly improve safety.
Six Sigma initiatives can be instigated.
Step 6
Step 9
Track metrics
Evaluate Performance
Critical to the success of any lean
As with any project or activity it is essential
programme is the need to track key metrics.
to report on key financial and strategic
They will provide information to identify the
measures to justify the continuing
most appropriate projects and can justify
investment in the process.
expenditure when required. ATS use the following in each of their factories to steer lean maintenance: Key performance indicators (KPI’s); Overall equipment effectiveness (OEE) and Mean Time Between Failures. (MBTF).
Step 7 Perform Root Cause Analysis (RCA)
Step 10 Continually improve As mentioned previously, lean is not a destination but a journey of continuous improvement, new or changing assets will mean a need to continuously update the programme of lean activities.
RCA is a method of problem solving that establishes the fault or cause of a problem.
Focusing on an effective lean maintenance
It is frequently used within the manufacturing
strategy will pay off both financially and in
operations and should also be applied in
terms of productivity. It will improve work
maintenance to establish machine failure
place satisfaction and improve safety. This is
or break-downs.
the core of manufacturing competitiveness. 03
Live safety Our first priority
HAZARD
OF THE MONTH
WINNER
Kulwinder Bhamber Locking mechanism Kulwinder Bhamber, Supply Chain/ Technician at Brierley Hill, was called out to look at a breakdown on a machine when he noticed an issue with the locking mechanism for the tooling. The spring loaded mechanism is supposed to lock the tooling into position for when material is required to be punched. Without this locking mechanism in place, the tooling can move freely and the materials will vibrate, putting both the machine and operator at risk. Kulwinder locked off the machine and assessed the job to get to the spring loaded mechanism, which required the 04
Chris Smith - Site Supervisor, awards Andy Kulwinder Bhamber, Supply Chain/Technician main head, to be stripped down. He found that the spring inside had snapped, so a suitable replacement was fitted and the mechanism was tested and confirmed as serviceable. This was an excellent identification of an issue that could affect customer safety, and a well-managed solution was engineered.
Proportional Test Rig asset #6511 During a reactive maintenance work order, Julian Burrows (ATS Technician at Havant) was required to look into a test rig electrical cabinet to check for tripped overloads, and visually observe input and output indicators. Upon inspection, a strong burning smell was immediately obvious and an overheated wire was identified. Julian immediately powered down and locked out. The fuse holder was too hot to touch so was left to cool, before the fuse holder and damaged wiring was replaced. This situation would have only gotten worse and could possibly have caused a short circuit and fire hazard had it not been found. Great work Julian.
Before
After
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ATS Wolverhampton Diamond award for safety
Andy Plant - ATS Supply Chain Specialist and Julian Budd CAT Facilities Manager
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“This is a great achievement for both ATS and Caterpillar, showing how we are both working in unison to improve our safety standards, this is just another great example of the importance of the great safety culture within the ATS business.�
Delight customers
Congratulations to ATS at Wolverhampton on achieving a Diamond award for Safety. All contractors on site, including ATS, have gone 731 days with no recordable incidents. Since ATS’ inauguration on 1st August 2010, there have been no recordable accidents. This is 1122 days of safe working within the department. The company’s primary cultural commitment is ‘Live Safety’, which is implemented in several ways, including:
• Daily safety talks • Dedicated on sight H&S representative • Safe working practices including things such as LOTO and PTA • Qualified and conscientious work force • Adherence to H&S laws and PPE requirements • Safety observations and safety training
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Developing people
TM
In January 2013, it was announced the strategic decision by ATS to implement a new global business system to improve our ability to effectively manage our most important resource – our people. Throughout 2012, multiple vendors were reviewed to ensure that the best system was selected, not just for today but for our future.
In addition to this the deployment of Workday will provide:
Workday was selected as the system for ATS and it went live globally from the 9th September 2013.
• Greater insight for managers
“Workday” is an Enterprise Business Management System, consistently rated one of the best and most innovative in the industry. Through Workday, our employees will have the ability to proactively manage their careers and professional development.
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• Self-service capabilities for managers and employees, eliminating over a dozen disconnected systems
to drive business results • More robust, timely reporting capabilities with information in the hands of decision makers • Cloud-based storage with 24 x 7 availability
Initial training for employees on the new system took place between the 26th August 2013 and the 6th September 2013 and we want to thank everyone for their participation. During September and the beginning of October, training will be supported with individual coaching sessions where required and weekly tasks will be issued with instruction sheets on how to complete processes within Workday. First week training focused on logging onto the system and updating holidays for 2013.
The Change Champions at each site available to support employees with Workday are as follows:
• Brierley Hill – Amy Nutting • Wolverhampton – Emily Mathews • Havant – Ross Tolliday • Titchfield – Karen Mattingly and Mike Ford
We would like to thank the Change Champions for their contributions and support of this project.
Pictured left Gemma Turner ATS Human Resources Manager 09
Enhance processes Recruitment ATS has set a goal to be a 110 million dollar business by 2023, and to achieve this we need to attract over 1,000 employees. To enable us to attract and recruit the best possible talent to complement our existing teams we decided to appoint our first Recruitment Manager, Anna Prince in August 2013. Historically ATS has relied on external recruitment agencies and bringing Anna on board is a first step towards a more integrated approach to resourcing our business. Anna has extensive recruitment experience and she will concentrate on implementing and delivering a UK specific recruitment strategy. Raising the profile of the ATS brand within jobseekers will be an important feature of her role. 10
Anna Prince - Recruitment Manager By approaching recruitment proactively through understanding our business and using modern recruitment tools, techniques and social media Anna will work on creating talent pools across the UK. This will add value to our customers eliminating their recruitment challenges in terms of time, cost and the risks involved, as ATS will be in contract with the right people with the right skills to support existing sites and to prepare in other areas as ATS expands.
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A note from Anna “For me ATS ticks all the boxes. I’m delighted to have joined ATS at this exciting stage and I’m looking forward to be part of its growth. Getting Recruitment right, especially when adding to existing teams, is crucial. I am interested in your views and any ideas you have for filling our vacancies and streamlining our processes and would be happy to hear from you.” You can contact Anna on the following details: Email: aprince@advancedtech.com Phone: 01536 311654
£1000 BONUS Recommend a friend and get £500 when they start employment with ATS and £500 after their first six months Terms: Payment is on completion of the probationary period.
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Driving
inn vation 100,000 manufacturing assets
eFactory Connect ATS eFactory Connect provides a 24/7 call centre for ATS Technicians, allowing them to dial-up to live maintenance specialists that can provide assistance on a wide variety of technical and maintenance related tasks. The purpose of the programme is to provide site technicians an additional technical resource to assist in developing solutions. The programme has already demonstrated enormous benefits in reducing downtime, minimising maintenance costs, and as a result a benefit to our customers.
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e
e
FACTORY CONNECT Watch here
400 Major Brands
eFactory Connect can help with… • Troubleshooting • Researching machine specific procedures • Finding Machine Documentation We are encouraging technicians to call eFactory Connect anytime a site needs help with any maintenance related issues that they are unable to resolve immediately; during the troubleshooting/repair process; and always before calling the OEM. The provision of this service will reduce costs for our customer as we will reduce the reliance on the OEM’s. We will improve the speed of fault resolution through immediate and responsive advice. It will also help the site improve its performance metrics through more efficient tracking.
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Demonstrate leadership Richard Aylen Best Practice award
During June Eaton asked ATS to support them on 2 safety projects which had been instructed by the Global Eaton H&S team. The first was a LOTO identification project where we needed to document and highlight the LOTO procedure on all of the machines. The second was to install tamper proof screws to all covers and guards. The onsite team did not have the resource to complete these projects in a reasonable time, so we recruited a Project Engineer to support these projects. Richard Aylen joined and from day one has demonstrated leadership in driving safety and delivering these projects. Both projects were completed on time and in budget to the great delight of the customer. Due to the success of these 2 projects, we have now been asked to undertake further projects on behalf of the customer.
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Richard Aylen - Project Engineer Awarded by Rick Lyford Eaton H&S Manager Richard was awarded a best practise recognition award by Rick Lyford (the Eaton H&S Manager) for his consistent high levels of safety. Richard clearly demonstrates what it means to Live Safety.
Predictive Analysis Initiative
A 3 day Predictive Analysis Initiative was held at Eaton Havant to support the Health Assessment which had been carried out on 8 key machines. The event was used to analyse the 8 machines using both thermal imaging and Ultrasound equipment in order to improve machine efficiency and eliminate energy lost through air leaks. 11 significant air leaks were located and repaired during the event, with a total air loss reduction of more than 63 CFM. 6 issues were detected and investigated through Thermal analysis, 1 of which was raised as an urgent W/O.
The event not only demonstrated the power of predictive maintenance, but also achieved customer savings of ÂŁ24,363.86.
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SERVICE
awards 1YR
Service award
Congratulations Binh La – Desk Side Technical Engineer at Church Crookham for achieving his 1 year service award.
3YRS Service award
Congratulations Paul Setterfield – Senior Technician at Havant, for achieving his 3 year service award. 16
G N I V A S T S CO
H T N O M E H OF T
Stefan Korn Eaton Havant Congratulations to Stefan Korn, Technician at Havant, for winning cost saving of the month. Stefan was contacted by a US colleague asking for help with translating a German machine document. The document was 70 pages long and required translation into English as quickly as possible. An internet search revealed quotations ranging from ÂŁ30 to ÂŁ70 per page depending on the speed and quality of the document. Stefan downloaded the 70 page document on to his own computer, printed it off and translated the entire document before returning the scanned document the following day. All the work Stefan carried out was done during his own time using his own computer. Not only has Stefan delivered an excellent cost saving to the company, but he delivered results and demonstrated leadership.
Stefan Korn - Technician at Havant is awarded by Andrew Purchase
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ATS Global
Advanced Technology Services Achieves Fastest Growing Company Accolade from Forbes! Due to an 85% three year growth rate, Advanced Technology Services continues to move up the leaderboard of America’s fastest growing companies. The list represents the most comprehensive look at the most important segment of the economy - America’s independent entrepreneurs. ATS joined the ranks of the top 5000 best performing businesses in 2011 and has continued its success, rising this year in the listings. Since 2011, the company has also added over 1,144 jobs, bringing its current staff totals to 2,999 employees. According to Jeff Owens, President of ATS, “Our considerable growth is due to two drivers in our business; the need for manufacturers to increase the performance and efficiency of production assets, and
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the new technology that ATS has brought to manufacturing. The US success comes soon after the UK division achieved a similar accolade in the UK’s Best Companies Ones to Watch List that also recognises high growth and dynamic organisations. Derek Hill of ATS UK commented that “It is our commitment to building and delivering value for our clients which continues to drive our success around the world.
CULTURAL COMMITMENT Live Safety Delight Customers
Develop People CONTINUOUS Enhance Processes
Drive Innovation IMPROVEMENT Nurture Relationships
Demonstrate Leadership Deliver Results A Way of Business, A Way of Life.
£500 BONUS is waiting for you
Did you know that there is a £500 bonus available to all staff for the successful introduction of new business? So if you have a contact in another manufacturing company that you believe would benefit from working with ATS, simply contact Keith Edmonds on kedmonds@advancedtech.com
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www.advancedtech.com Advanced Technology Services UK Ltd Unit 4 Beechwood Cherry Hall Road Kettering Business Park Kettering Northamptonshire NN14 1UE Phone: +44 (0)1536 311650 Email: info@advancedtech.com
Key Contacts Managing Director Derek Hill djhill@advancedtech.com Sales & Marketing Keith Edmonds kedmonds@advancedtech.com Continuous Improvement Steve McCarthy smccarth@advancedtech.com Human Resources Gemma Turner Gturner@advancedtech.com +44 (0) 1536 311657 - Direct +44 (0) 7527 289917 - Mobile +44 (0) 1536 416965 - Fax