Reduction of faults and minor technical interruptions

2 days

course code 3. 17

What is the course for

#1

Increase the operational availability of equipment

#2

Reduce technical faults and minor technical interruptions of the equipment

#3

Create a data collection system for faults and minor technical interruptions

Every company that decides to invest in equipment of any kind will encounter failures and minor technical interruptions. Modern engineering maintenance techniques tell us that such events are avoidable, that machine reliability is heavily influenced by people’s “habits”. Reliability begins when people’s attitudes towards the pieces of equipment go from “putting something in place in the event of a fault” to the more proactive attitude of “anticipating potential problems and acting before a fault occurs.”

This training course is focused on sharing a series of proactive “habits” that will allow participants to develop a mentality geared towards eliminating all technical interruptions.

 

Goals

  • Increase the equipment’s operational availability
  • Reduce technical faults and minor technical interruptions
  • Create a data collection system for faults and minor technical interruptions
  • Create a company culture aimed at eliminating equipment related loss.

Addressed to

  • Production Managers
  • Maintenance Managers
  • Production Supervisors
  • Process Engineers
  • Operators

Contents

Preliminary activities

  • How to set up a data collection system of machine events to calculate OEE and stratify losses resulting from it
  • How to collect data related to faults and minor technical interruptions
  • How to define priorities for intervention
  • How to select and monitor the most suitable performance indicators for the project
  • How to define SMART fault reduction targets and minor technical interruptions.

Restoring critical areas to their ideal conditions

  • How to identify and define a critical area
  • Restore a critical area to its ideal operating conditions
  • Optimising all of the 4M (man, machine, material, method) operating standards
  • How to extend the new operating standards to those in charge

Eliminating faults and minor technical interruptions by  problem solving

  • How data collection evolves after restoring to ideal conditions
  • How to prioritise residual anomalies using Pareto charts
  • How to apply problem-solving tools to reducing faults and minor technical interruptions
  • How to verify that the achieved results are maintained.

Preventing failures and minor technical interruptions

  • Develop a fault analysis framework that uses visual management
  • How to improve preventative maintenance by employing an x-matrix for faults
  • How to construct a quick reaction system for minor technical interruptions as they occur

PRACTICAL EXERCISES:

  • Experiment with defining priorities for intervention using Pareto charts
  • Experiment with restoring a critical area to its ideal conditions
  • Experiment with analysing a fault or minor technical interruption to identify its cause at source
  • Experiment with compiling and analysing the QX Matrix for faults and constructing a table of “trigger points” for reacting to minor technical interruptions

You will experience

  • The different methods of data collection
  • Pareto charts
  • Autonomous maintenance tags
  • Timetable and standards for cleaning inspection and lubrication
  • OPL (One Point Lessons)
  • SOPs (Standard Operating Procedures)
  • The 5W + 1H
  • Cause and effect diagrams (problem-solving technique)
  • The 5 Whys (problem-solving technique)
  • QX Matrix of faults
  • “Trigger points” for reacting to minor technical interruptions.

Download the in-company training catalogue