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Oerlikon Fairfield – Lafayette

Journey to Excellence Building a Culture of World Class Asset Maintenance & Reliability Dale Deem CMRP- Reliability Engineer Oerlikon Fairfield Manufacturing February 21 , 2018. Oerlikon Fairfield – Lafayette. Largest Gear Manufacturing Facility in North America.

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Oerlikon Fairfield – Lafayette

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  1. Journey to ExcellenceBuilding a Culture of World Class Asset Maintenance & ReliabilityDale Deem CMRP- Reliability Engineer Oerlikon Fairfield ManufacturingFebruary 21, 2018

  2. Oerlikon Fairfield – Lafayette Largest Gear Manufacturing Facility in North America Oerlikon Fairfield Confidential

  3. Product Capabilities Extensive Capability for Custom Gear Manufacturing • Specialty Gears and Shaft Components • Spur, helical, bevel • Internal, external • Shafts over 3M in length • 20mm to over 2M Ø • Finishing to AGMA 14 • In-house heat treat capability

  4. Quality is very important Do things right the first time • Even if you don't make a product you still need to work this way. Rework of any kind wastes time and resources. Scrap costs money and wastes time and often causes us to deliver late to our customers….resulting in an unhappy customer.

  5. How did we get to this point in time? • A long standing tradition of “Can Do” attitude • Dedicated and Mature Workforce • A vast amount of Tribal Knowledge • A diverse inventory of Equipment from Legacy to Latest technology

  6. Opportunities for Improvement • Most of the Assets are at least 7 or more years old • Aged EAM System (AS400) • Inadequate PM Plans & Task Lists (or none at all) • Inadequate or Missing BOM’s • Maintenance Library is not well maintained • No standardized Maintenance Work Flow “Squeaky wheel gets the oil” • Lack of Documentation

  7. Oerlikon Guiding Documentation • *OP 4.09.3 Preventive Maintenance • Purpose – That suitable Preventive Maintenance is completed in a timely manner to ensure continuing Process Capability. • Scope – All Preventive Maintenance is performed on Production Machinery. * - OP = Operations Procedure

  8. Guiding Documentation • ISO9001-2015 (Must Comply with by June 2018) • Section 6.3 – Infrastructure • Section 6.3.1 – Plant, Facility, and Equipment Planning • Section 6.3.3 – Contingency Plans • Section 7.3.1.1 – Multidisciplinary Approach • Section 7.3.3.2 – Manufacturing process design output • Data Quality, Reliability, Maintainability, and Measurability • Section 7.5.1.4 – Preventive and Predictive Maintenance • Planned Activities • BOM • Maintenance Plans & Task Lists

  9. Guiding Documentation • ISO/TS 16949:2009 (June 2018) • 3.1.7 – Predictive Maintenance – Activities based on process data aimed at the avoidance of maintenance problems by prediction of likely failure modes • 3.1.8 – Preventive Maintenance – Planned action to eliminate causes of equipment failure and unscheduled interruptions to production, as an output of the manufacturing process design • 8.2.3.1 – Monitoring and measurement on manufacturing process • “…reaction plans when acceptance criteria are not met. Significant process events such as tool change or machine repair shall be recorded.”

  10. Where to Start • Begin with the end state in mind • What does good look like? • What is World Class? • What will it take to get there? • Resources • Manpower • Financial • Facility • Contractor • Accept that this is not a “Microwave” process rather a “Crock Pot Process”. The current state did not develop overnight

  11. Develop a Comprehensive Plan • Methodical • Detailed • Milestones • Do not press forward unless the preceding steps are in place • Solicit support and “Buy in” • Operations are your In-house Customer • The end user is the Ultimate Customer • The plan is an “Us” plan not “We vs. Them” • Utilize Best Practice Data and Information (SMRP BOK)

  12. Maintenance & Reliability Plan • Over simplify • Make plan easy to understand • Be prepared to explain as a process • Remind yourself that this is something new to your facility • Expect Pushback • Explain the features and benefits • Explain the “What’s in this for me” to you audience • Let’s Work Smarter, not Harder • Baby Steps • The journey of 1000 miles begins with one small step • Solicit support

  13. Oerlikon Fairfield PM & Reliability Improvement Plan

  14. Criticality Assessment

  15. Finished Criticality Assessment

  16. Research and Organize PM & Work Order History Problem Statement Remedy Statement

  17. Work Order Level

  18. Work Order Level Capture # Work Order Hours % of Hours Work Order Type

  19. Machine Run Hour History We use machine run hours which are entered by operations personnel into AS400 to determine when PM’s should be performed. Most Mazak equipment have a 1500 hour and 3000 hour PM

  20. PM Task List

  21. PM Task List

  22. PM Task List

  23. PM Task List Notes & Comments Use technicians notes for follow up work orders Also make updates to PM tasks

  24. PdM Methodologies

  25. PdM Methodologies Recommended action Impact Potential

  26. Data Assimilation

  27. PM Planning & Scheduling Meeting

  28. PM Schedule PM’s Upcoming and Scheduled in weekly PM planning Meeting Completed PM On Time PM Urgently Due (See Note)

  29. On the Horizon • Vibration Spectrum Analysis • Reliability Awareness Training for Operations • Storeroom KPI’s • Inventory Optimization • Real Time Asset Monitoring • New EAM

  30. Questions?

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