dematic best maintenance practices track/session 2... · best maintenance practices for the real...

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Best Maintenance Practices for the Real World

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What is the philosophy of the organizational stakeholders? Reactive: Run to Fail Proactive/Predictive: Prevent issues before they occur

Ownership Strategy

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Why is Maintenance so important?

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Cost of downtime

Productivity

Missed shipments

Expedited shipping

Equipment life

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Auditing as part of a responsible maintenance program

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- Maintain Increased reliability Manpower efficiency On-time shipments

- Monitor Remote diagnostics Alert monitoring

- Continuous improvement Safety Training Parts management

- Modernize

Longevity

Performance

Functionality

- Audit

Wear/damage

Maintenance practices

Looming obsolescence

Preparedness (parts, etc.)

Practices (safety, etc.)

Design (still match need?)

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Discovering impending problems More flexibility in

planning repairs the earlier issues are detected Getting operational buy

in on fixing it now or rolling the dice An outside set of eyes

will catch things that are problems but considered situation normal for the crew

Why audits should be part of every maintenance program

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Developing your audit schedule

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Start somewhere and adjust as time goes on Tune the audit frequencies based on category and experience. Monitor things like…

– Have I seen changes in system availability? – Have I gotten surprised by obsolescence? – Have I gotten caught with insufficient budget?

TYPICAL AUDIT SCHEDULE

AUDIT CATEGORY Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4DesignOwnershipModernization

YEAR 1 YEAR 2 YEAR 3 YEAR 3

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Strategies for auditing

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Who should conduct the audits? – Internal vs. external – Frequency Who should you talk with while auditing?

– Operators – Maintenance – Senior management

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Non-intrusive methods and tools

Daily Audits

8

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Equipment

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What type of items should you look for during an equipment audit?

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Tablet with stylus

Auditing tools

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Documenting audit results

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Computerized Maintenance Management System (CMMS) Benchmark system availability

over time Document audit findings Develop correlations Define the cost of ownership Establish trends over time

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Training

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Weekly training sessions

Peer to peer training

Not top down training

Each person researches topic

Make presentation to the team

Access manuals etc. for research

Obtain comprehensive view

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Utilize data to increase efficiencies

– Call center activity – Remote alert monitoring

activity – CMMS reports

Advanced tools and data analysis

13

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System Performance Indicators

– System Uptime by Equipment

– Mean Time Between Failures

– Mean Time to Repair – Total Count of Errors – Top 4 Errors – Fault Listing – Parts Management – Photos

Measuring performance and progress through KPI reports

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System Uptime

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Target 98% Track sub systems so

things don’t get lost in the averages Graph results

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Mean Time Between Failure

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Mean Time to Repair

17

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Total Count Errors

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Top 4 Errors

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Parts Management

20

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Are you getting the most from your CMMS? – Reporting – Ability to connect with a mobile device – Inventory management Barcode parts and use a scanner to

identify Automated re-order

– Web based solution – Generate work orders by technicians

skillset

CMMS

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Dematic Sprocket Features

22

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Specialty Tools

23

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AGV Idler Wheel Fixture

24

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Cost < $500

Drive Plate Removal Tool

25

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Cost < $500

Drive Assembly Stands

26

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Cost < $500

Tow Dolly

27

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Downtime Saving Practices

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Solutions for Unstable Power

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Many devices like PickDirector Net Controllers, Scales, PLCs are sensitive to voltage fluxuations and power surges Adding battery backups will protect these devices and therefore improve the

uptime of the system

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Three Phase Voltage Monitor

30

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RS200 Transition Bed Belt Tracking Stand

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Thank you