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Southeast Regional Maintenance Center Lean Repair Industrial Plant Equipment Kaizen

Southeast Regional Maintenance Center Lean Repair Industrial Plant Equipment Kaizen. Presenters: Jim Holland, JR Dunn, Joe Nettuno, CDR Mike Hall, MMC Chris Royal, Paul Lazarowski Lean Coordinator: Jim Holland 6 Apr 06. Excess Material Update. Excess Material Update.

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Southeast Regional Maintenance Center Lean Repair Industrial Plant Equipment Kaizen

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  1. Southeast Regional Maintenance CenterLean RepairIndustrial Plant Equipment Kaizen Presenters: Jim Holland, JR Dunn, Joe Nettuno, CDR Mike Hall, MMC Chris Royal, Paul Lazarowski Lean Coordinator: Jim Holland 6 Apr 06

  2. Excess Material Update

  3. Excess Material Update - Plant Stock – Value increased as anticipated due to shop turn-ins. - Project Stock – No problem, just fluctuating with workload. - Ordered not rec’d TECO – If met shipping status, transfer to Plant Stock. If not shipped we request cancellation. - Aged > 1 year – 1832 of 1987 line items are original RDIS items. Logistics working to properly dispose (MTIS, RRAM, etc.) 1109 new line items ready for RDIS cycle. - Xfer to RAM YTD – 170 line items to date.

  4. Other Items to Report Logistics • Point of Use Storage (started with REDIS funds) • 172 candidates identified by Planning • 94 ordered and received • 31 to be ordered • 47 show no demand since 2004 (under investigation w/shops • 8 of 94 line items have been issued from POUS • Evaluating process; exploring the in shop POUS, possibly using WTD Shop as prototype • Reserve/Active Issue • Redistribution Program (RDIS) • 155 line items totaling $133, 000 pulled for resale • $114, 000 of $133,000 received • $94,000 used to start POUS • 1832 of original 1987 RDIS items possible RRAM transfer candidates; there is more.

  5. Other Items to Report Logistics • BLDG 191 • Inventory complete, started entering into NEMAIS (~260 items). Working to ID many items. • Verifying condition and usage, many will be turned back in to Supply (DLR’s), remainder will be in NEMAIS for RMC visibility.

  6. IPE Management Review industrial plant equipment inventory and support processes and target this area for continuous improvement efforts. Project Goals: Identify the RMC IPE Manager. Inventory existing Fleet IPE supporting Fleet Maintenance; identify any excess IPE. Achieve a standard approach to IPE maintenance & support at SERMC, continue honing the Prototype. Continue working with Mr. Ed Hall, CNSL, to provide budget support for OMN and OPN funded IPE, until another process is established. Identify & share best practices. Finalize Prototype for annual maintenance in the Inside Machine Shop, and start including other shops one at a time into NEMAIS. IPE Kaizen

  7. Project Leader: JR Dunn Project Team Members: JR Dunn Paul Lazarowski MRC Norm Hudson MR1 Jay Cole MR2 Matthew Keller Jim Holland IPE Kaizen

  8. IPE Kaizen Measures

  9. IPE Repair & PM • Overview of the process through which SERMC manages IPE repair and Preventive Maintenance • Mr. JR Dunn is the IPE Manager • Funding acquired through Mr. Ed Hall, CNSL for new repair parts and replacement equipment; TRF Kings Bay conducts repairs. • Work execution and documentation – Difficulty with Daily/Weekly checks on schedule – working with SWRMC to resolve – may place at all work stations (laminated) for shops to manage. Monthly and above appear on track. Using TM/PMS to establish maintenance requirements. • QA – Shop Supervisor for Daily/Weekly checks. Developing feedback system in NEMAIS for use as maintenance spot checks by Shop Supervisors/IPE Manager. • NEMAIS is inventory system of record – Working Inside Machine Shop to establish best way to manage/schedule maintenance outside of present system for PM.

  10. IPE Funding • Overview of how IPE support is funded at SERMC • Repair parts & labor – Using TRF Kingsbay / Ed Hall, CNSL – Repair approach is first to make repairs in house. • Service contracts- Rare, but available and used. • Replacements – Mr. Ed Hall, CNSL

  11. Changes: Created base for sample scheduling product in NEMAIS (Training Client) Posted daily/weekly checks on machines not covered by current PM system Acquired TM’s for all 935K equipment Results: Once finalized (~17 Apr) will begin implementation into Production Client with goal date of 31 May Able to obtain PM requirements IAW Manufacturer 30 Sep for remainder of SERMC IPE Kaizen Process Changes Made

  12. IPE Material Kaizen Pictures Transaction IA05 Equipment manufacturers can be designated as Groups. CNC is used in this example. Under the manufacturer CNC, each model can be specified. Three are shown as an example.

  13. IPE Material Kaizen Pictures Each PM recommended by the manufacturer can be listed under the model type. The Component button is used to specify what material is required for each PM.

  14. IPE Material Kaizen Pictures The Maintenance Package Overview is used to specify the frequency to perform each PM.

  15. IPE Initiatives Local lean methods used to improve IPE management • Checked during every event • Finalize Prototype with Machine Shop • Utilize NEMAIS as resource management tool Local lean methods used to minimize IPE down time – NEMAIS • NEMAIS for working and scheduling • Continuous feedback for process improvement

  16. Lessons Learned: Use NEMAIS from the start instead of experimenting with a different program due to lack of knowledge with NEMAIS,. Start a team instead of individuals Recommendations: Continue the process for getting SERMC IPE into NEMAIS (as required for all RMC’s with NEMAIS). IPE Kaizen

  17. FY06 Lean Program Overview

  18. Preparation for June Timekeeping VTC • Timekeeping Three Phase Plan: • Designate primary/alternate timekeepers (Complete) • Conduct training of all timekeepers (Complete) • Produce management tool to review and spot check Command timekeeping data (In-progress) • Timekeeping Products: • Missing time • Lost time • Top 5 overtime usage cost centers • Accuracy of Charges in the system: • In the past no formal method of conducting spot checks/QA. • Currently implementing as part of Phase 3 • After the FMO POAM was sent out, SERMC quickly evaluated our Command Time Reporting as deficient in accounting for military time and civilian missing time. Significant progress has been made and with a second round of training, and spot check implementation, SERMC is on the right track with Command Time Reporting.

  19. Other Items to Report • PDA’s for SISCAL approved, purchased by SERMC and making arrangements for training before initiating 1st project here. • Continue shops, but at a slower pace awaiting RMC Production makeup, and due to personnel shortages in some shops • JOBSHOPLEAN – scheduled to do Pilot with Dive Shop, Gas Turbine Shop and possibly Diesel Shop 28 May – 25 Aug. Providing data for initial evaluation. • Six Green Belts, plus 2 more in May (CO/PIM), with local course scheduled in July for 22.

  20. Other Items to Report • Working on Reserve Assist – LCDR Ed Galluccio (NADEP) scheduled over 3 weeks (Apr-May)

  21. Keep thinking Lean To be continued

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