Factory Asset Management. For Heavy Equipment Manufacturers

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1 Factory Asset Management For Heavy Equipment Manufacturers

2 From Prototype To Final Test. 10 Steps To Increased Asset Performance In The Heavy Equipment Industry. With increased spending on industrial and construction projects, additional equipment manufacturer competitors and new products and technology coming to market faster, heavy equipment (HE) manufacturers are under pressure to not only meet market demand quickly but also be able to respond to volatility in the marketplace and their supply chains. The push toward Lean manufacturing and developing world-class standards are now table stakes in this highly competitive industry. And challenges abound. Infrastructure, compliance and capital investment must be reckoned with to succeed. With over 68 percent of all heavy equipment manufacturing plants more than 20 years old, annual capital investment is high. In fact, heavy equipment manufacturing has one of the highest annual investments in capital equipment of all manufacturing. Add that to a workforce of 2,700 skilled technicians supported by a full circulium of progressive training programs, and ATS has the resources and vision to keep your factory running better now and into the future. From helping you create a safer production environment to achieving your ambitious OEE goals, ATS provides a process to help you increase quality and shareholder value. See how ATS can eliminate waste, drive continuous improvement and open up hidden capacity in your manufacturing infrastructure. Follow the 10 steps below to increase asset performance and call us for a free, no-obligation assessment today. Capturing market share opportunities, introducing new products and reducing cost to manufacturer require investment in machinery, technology and skilled labor to operate and maintain it. And unlike manufacturers of the past, not all manufacturing functions are considered core. In fact, clearly 94 percent of all heavy equipment manufacturers outsource some functions already. And now 50 percent are outsourcing maintenance activities. The availability of skilled labor, increased complexity of the equipment and the need for increased production equipment are all issues heavy equipment manufacturers face. And that s where Advanced Technology Services (ATS) can make a dramatic difference. ATS makes factories run better for some of the world s most successful manufacturers. Through a standardized process of asset optimization, ATS can increase production asset performance by 30 percent or better. That adds up to more product out the door, less constrained equipment and fewer capital investment dollars needed to maintain production. 1. Reorder It. Five S When you put Advanced Technology Services to work in your factory, you ll see noticeable improvements fast. Using the practice of 5S, tools are sorted. Workspaces are straightened and cleaned. Next processes are standardized for higher productivity. And the concepts are internalized for sustained improvement and success. At first it might seem like a small thing, but it sets the stage for the dramatic transformation to come

3 2. Restore It. Total Productive Maintenance Imagine your aging manufacturing assets working like they were brand new again. It s no dream. It s ATS Total Productive Maintenance (TPM) program in action. To begin with, ATS works with your operators to identify key wear points and trouble spots. PMs are designed around how the operator and machine work together. Machines are cleaned, repaired, repainted and re-launched back into production. Often times beating previous performance records by more than 300 percent. 3. Map It. Balanced Scorecard Going somewhere new without a map can be difficult. That s why ATS helps you develop a strategy map that shows the impact between improvements in maintenance and financial performance. It s called the balanced scorecard. And it s the measurement tool that helps you maximize shareholder value through improved productivity and revenue growth. It s a big concept that creates a measurable and most of all an accountable difference in your bottom line. 4. Track It. Key Performance Indicators Getting to the root of the problem requires data. That s why ATS digs deep into the facts and works with you to develop Key Performance Indicators (KPI) to plot progress as we help you maximize your production goals. OEE, machine availability, uptime and meantime between failure are all diligently plotted and fed into 3-up charts. It s how we keep track of production. Increase output. And judge the success of our maintenance activities. 5. Plan It. Planner/Scheduler Think of how effective a maintenance team could be if they could predict when a machine is likely to fail. Well that s exactly what the ATS planner/scheduler has at his disposal. The ATS Knowledgebase is quite possibly the largest database of machines that exists in the industry. And it comes from our experience of working on our customers machines for over 20 years. From robotics to CNC machines, ATS has the knowledge to put together a comprehensive maintenance plan for every manufacturing asset in your organization.

4 6. Predict It. Predictive Technologies Through ATS suite of predictive services, we can head off downtime before it stops you cold. With technologies like thermography that pinpoints electrical and mechanical hot spots to vibration analysis that detects damaging vibration, ATS predictive tools can extend the life of your critical assets. Add in disciplines like Reliability Centered Maintenance (RCM) and we can also help you predict machine reliability and develop the best maintenance plan for your production assets. 7. Find It. Root Cause Analysis Root Cause Analysis trigger points are developed from key performance indicators. So when a threshold limit is reached based on time down or cost, our professional staff goes to work to get to the root of the problem, fast. What it means to you is uninterrupted machine output. And since all key performance indicators are charted, you have visibility to critical machine data through our web enabled efactorypro CMMS system. 8. Fix It. 6 Sigma Once the root of the problem is uncovered the discipline and rigor of 6 Sigma is put into play to further Define, Measure, Analyze, Improve and Control (DMAIC). Through the DMAIC process, it is not unusual for ATS to save customers thousands of dollars in lost output opportunity by creating improvements in the current system. ATS will also use the DMEDI process (Define, Measure, Explore, Develop and Implement) to develop new, innovative manufacturing solutions for customers. 9. Evaluate It. Site Audit After the ATS plan is in place, site audits are performed to evaluate the maintenance organization, examine maintenance practices and machine performance. Safety standards are reviewed and improved. Planning and scheduling is audited and 5S initiatives are refined and enforced. Cooperative maintenance is evaluated and training of the ATS maintenance staff is enhanced. And last but not least, document management and inventory purchasing is scrutinized for clarity and cost efficiency. It all adds up to provide the highest quality and most consistent service delivery to our customers.

5 10. Optimize It. The Result It s not unusual for our customers to report up to a 30 percent or better improvement in output. With some customers reporting OEE numbers into the 90 to 95 range. Scrap is commonly reduced by as much as 40 percent. And machine availability can even double after the process is in place. But what this means to you is the ability to remain competitive in a fast changing global economy by focusing on what you do best. Outsourcing your maintenance with ATS lets us focus on what we do best making your factory run better. Call for a free, no-obligation assessment today.

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