Computerized Preventative Maintenance Program for the Automotive Industry - Utilizing Palm Pilot Radio Frequencies 2002-01-0291
The authors will present a self contained computerized program to reduce the cost of typical in plant maintenance and improve the first time quality of manufacturing. This program will be designed for the major manufacturer and the smaller sub-contractor to reduce waste and improve the overall cost reduction of manufacturing. This Presentation will present a hands on demonstration for the use of the Palm Held Computers and Clipboards for Preventative Maintenance.
As we look into first run capability, we will focus on such aspects as: waste stream management, job descriptions, work orders and trend analysis. Goal setting must be a part of the Manufacturer/Contractor relationship and thus be quantifiable and realistic. Preventative Maintenance is often the most ignored aspect of Manufacturing in order to get the production numbers off the shipping dock. This Program will lead to a more harmonious relationship of shipping parts and producing them in a less costly Environment. An OEM paint facility will be used as the demonstration point.
Emphasis throughout this paper will be on the Team Approach to maximize the Documentation for the ISO series process. A Computerized Maintenance Management System (CMMS) model will be presented to affect maximum utilization of computerized data banks. Pitfalls of starting a CMMS Program will be discussed in association with comments on the customized data bank.
This paper reviews the basics of Preventative Maintenance with a CMMS Program and allows us the capability of tracking and solving problems to enhance our first run capability produced by EPAC Software Technologies of Warwick, Rode Island. The Manufacturing model will be an OEM Paint Facility. New Equipment and technology will be demonstrated during the Presentation.
Maintenance dollars and equipment performance has a direct cost effect on the entire Organization. In the measurement / documentation of related issues, quantitative performance becomes a major factor in how successful we are with any plan or strategy. Reliability, safety, training and efficiency are just a few of the objectives to be measured and documented in the PM Program. Reducing the cost of Manufacturing (overtime, down time, accidents or inventory; to name a few) is an effective way of measuring the Performance of your Preventative Maintenance Program.
· Savings through Labor Productivity
· Savings through Material Management
· Savings through Equipment Productivity
· Measuring the Savings through:
· Inventory Controls
· Equipment log's
· Breakdown Analysis
The Paint Shop, as we know it today, offers significant dollar risks in Cost Per Unit (CPU) accounting within a Total Fluids Management Program. As we pursue the latest Technology in production, air, water, fluids, equipment Management, we are finding their sensitivities to the Quality of the Product and the cost of the CPU. Future Preventative Maintenance Programs will be determined by the Supplier in conjunction with the cross effects of Fluids, Environment and Painting Operations. A dirty spray booth, grates, flood sheets or exhaust fans will not allow for the proper air flow/wash of over-spray, thus effecting the first run capability and CPU. No matter how current the existing technology is in your facility, we need to establish a Program to control the Basics of a Paint Shop, regarding - Air, Fluids, Environment and Paint Operations. When a Paint Operation is allowed to become compromised by inadequate basic cleaning and maintenance functions, the Quality first run figures will decrease at an abnormally higher ratio.
Throughout the past five years, and well into the next millennium, there has been a continuous economic growth. With over-capacity and waste-stream management, our global economy has become more environmentally responsible for “Green Products and Waste Streams” New Technologies, Preventative Maintenance and Cost Reductions will be recognized as a major contributor of a more environmentally safe product. Government Programs, Green Groups and Consumer Action Groups will demand new programs to replace, what we thought of as safe measures - Twenty years ago. Documentation for waste reduction will be a local City and State requirement, if not already. The process of eliminating waste before it becomes an Environmental Issue will be the standard. The backbone of such an “Environmental Challenge” will be Preventative Maintenance Issues and how they are documented in the ISO 140000 Series and Maximum Available Control Technology (MACT) for controlling Hazardous Air Pollutants ((HAP's) defined by the Clean Air Act.
Defining the service in a maintenance business is not as simple as it appears. Not only is the type of Service necessary to define, but also the time frame in which the service will be provided in. In an attempt to define the types of services, let's consider the following:
· Is the equipment ready and available to perform planned/routine maintenance activities?
· Will the cost to shutdown the equipment be less then the cost of equipment failure?
· Is the equipment downtime a problem?
· What are the environmental/production impacts of equipment downtime vs. failure?
A Maintenance Management Program will…
· Identify Chronic failures
· Assist in Minimum Inventory levels
· Provide for Effective Planning and Work schedules
· Measure Quantifiable Data against Performance Records
· Document Data for the appropriate ISO series Recording
· Perform to Budget restraints
· Reduce Backlogs and Supply chain issues
· Improve and Control Waste Stream management
· Identify and improve Safety Programs
· Provide Effective management of the Work Force
Know the depth of your system and the value received as a Corporate benefit. What are the current features of your system and how do they compare with the systems that are currently on the market place? What was the last new version of your system and how are your Training programs being adhered to? Will your CMMS System interlock with the other Corporate applications? Have a complete control on dollars saved as a benchmark? These and a few more questions will be addressed during our presentation.
The material presented here today is not “first time information” that will revolutionize your Facility, however, it is a systematic approach to improving the Quality issues, which will improve the bottom line and satisfy the Customer.
From the outset, the Program of Improving a process, it must identify what the objectives are designed to accomplish and what they are not. Our goals will support our mission of improving the overall effectiveness of the PM Program.
As we present certain activities or objectives to enhance our chance of success, we shall be discussing the following basics of the Paint-shop in the Automotive sector:
· CMMS / Computer Model
· Dirt Defect Analysis
· Total Air Management
· Preventative Maintenance Program
Management support for the project is not only essential but also critical in all phases of a Preventative Maintenance Program. The goals and objectives must present a clear direction for all personnel to follow to insure the Plant success. Activities must be identified as either supportive or non-supportive.
Workers evaluations will become an integral part of the overall program. An effective in-house communication program, with training, will promote this program.
The validity of any program should be measured as quantifiable results towards the mission of the Facility. The Preventative Maintenance Program as we know it today, will be a tremendous factor in identifying “Cost per Unit” and “Warranty Programs” of the future.