Contributing Re.engineer: Roger Tetrault
Challenge: One of the key functions of maintenance within a manufacturing facility is to safely execute repairs and maintenance activities in a cost competitive and timely manner. Many maintenance organizations struggle with this objective mainly because of the complex process it takes to complete work orders. From scoping to planning to ordering materials to actually scheduling the work, all elements of the work process must be carried out with no errors in order to avoid delays. One facility averaged 47% schedule compliance and a work order cycle time of 87 days and was looking to identify a way to eliminate non-value added work to increase their performance.
Solution: The team of maintenance staff partnered with each other to develop a troubleshooting process that enabled them to quickly identify whether or not a work order was needed before creation. This process also allowed them to develop better scope details for activities that needed work order planning (materials to order, other crafts that were needed, hours to complete the work, etc.).
Results: As a result of their efforts, they were able to realize a 26% increase in schedule compliance (from 47% to 73%) and a reduction of 68 days of work order cycle time (from 87 to 19). One secondary improvement to this process was the 47% reduction of the # of instruments in manual, from 4.7 per month to 1.6 per month.
mAINTENANCE PRODUCTIVITY CASE STUDIES
This section of case studies feature improvements that align to increasing maintenance productivity.