Priceless Therapy for a Midlife Crisis Track 6 Session 6
Scot Filgis Regional Resident Maintenance Project Manager Dematic john.filgis@dematic.com 616-780-6086 2
Abstract At a certain age, automation gets wrinkles and forgetful. The key to sustained and increasing return at 5, 10, 20 years of service is getting thorough regular checkups. This critical lesson will help you define, schedule and conduct life-giving Ownership Audits for your investment. An experienced caregiver will teach you how to audit safety, training, parts inventory, obsolescence, software currency and CMMS data. It's cheaper than buying a sports car. 3
Agenda Introduction Prolonging the life of your material handling system Strategies for auditing Documenting audit data Data analysis Advanced metrics and scorecards 4
Why consider audits? It s your annual physical, not surgery. You need to conduct them. What you don t know can kill you. Pay me now, not on Black Friday. If you don t schedule them you won t do them. Make them part of your annual Ownership Strategy. 5
Maximizing your return and utility Auditing as part of a responsible Ownership Strategy - 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?) 6
Categories of Audits* 1) Design Audits - After the Break-in Period Check Your Oil: Design Assumptions - Has the original design data materialized as planned in terms of elements such as order mix, volume, sequencing over time, etc.? Design Specifications - Has the installed Solution met the promised operational parameters and thus delivered the functional and business benefits promised? * in addition to the daily tours we will discuss later 7
Categories of Audits 2) Ongoing Ownership Audits - Making sure that the implemented Ownership Strategy is meeting the needs of the enterprise: A Quality Audit covers the Reliability and Availability of your technology assets. Parts Audit includes a review of the spare parts and consumables inventory and compare that to the current appropriate inventory Data Analysis of the system performance history. Dig deep into your CMMS and WCS error logs. Maintenance Scorecard benchmarks the quality and effectiveness of your Maintenance Program 8
Categories of Audits 3) Periodic Modernization Audits - Focused on the effect of time on your technology and extending the useful life of your investment: Obsolescence Are there manufactured or 3rd party components that are now or will soon be unavailable? Mission Has your business changed in terms of order mix, customer demands or product form factor? Technology Upgrade Opportunities - There may be financially justifiable opportunities to replace an outdated component or subsystem in your system with a modern version to improve performance, reliability and/or function. 9
Categories of Audits 3) Periodic Modernization Audits (cont.) Safety and Standards Studying your older application and applying today s standards driven by improved tools and more diligent Performance Enhancements New developments in motor control, logic, sensing and software allow opportunities for safely increasing the throughput of older assets. Wear - Diligent assessment of all wear and motion and control components for longevity and risk Capacity If you are outgrowing your system in terms of throughput and/or storage volume, is there a way to use the engine of your system and simply add size with added equipment and controls. 10
Developing YOUR Audit Schedule Start somewhere and adjust as time goes on Tune pace 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 YEAR 1 YEAR 2 YEAR 3 YEAR 3 AUDIT CATEGORY Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Design Ownership Modernization 11
Strategies for auditing Who should conduct the audits? - Internal vs. external - Frequency Who should you talk with while auditing? - Operators - Maintenance - Senior management 12
Strategies for auditing How many faces do you see? - Average see 4-6, sensible see 8-10, the best see all 11, paranoids see 12 or more 13
Strategies for auditing How many did you see? 14
Daily Tours Walk the system Quick check Observe Listen 15
Equipment What type of items should you look for during an equipment audit? 16
Equipment What things should you listen for during an equipment audit? - Knocking sounds around the drive - Ticking sounds - Air leaks - Chain chattering - Belt lacing rubbing - Conveyor starting without an audible horn 17
Auditing Tools Borescope (approx. $300) 18
Auditing Tools Clear covers 19
Auditing Tools Painters tape and tags
Auditing Tools Tablet with stylus 21
Auditing Tools Enterprise Asset Management System (ala CMMS) - Benchmark system availability over time - Document audit findings - Develop correlations - Define the cost of ownership - Establish trends over time 22 22
Auditing Tools Vibration analysis equipment ASRS Drivetrain anomalies Thermal imaging Electrical current draw and bearing issues Oil analysis Overheating, metal fatigue Die penetrant testing Hidden structural failure Accelerometer Accel/Decel optimization Hardness testing Bearing surface life (wheels, rails, etc)
Personnel / Training What is the appropriate level of staffing? - OEM preventative maintenance requirements - Operational support - Contractor management 24
Safety Electrical safety training Working at heights Hot work cutting and welding Hazard identification and risk assessment Fall prevention Mobile equipment Confined space Emergency response 25
Parts Audit Create or print the master list - Verify quantities and locations - Review usage to determine the correct quantities of spares are on hand Example Audit 26
Software Audits Software should be evaluated based on its function, value, risk and continued need. Typically less expensive Internal External Pros Cons Pros Cons Outsourced company is responsible for identifying software holdings Takes resources away from their normal duties Access to more diverse programs to identify holdings Will not know your systems or processes Less experience More experience More expensive Usually completed quicker 27
Obsolescence Create an equipment spreadsheet - Review with OEM and discuss options Example obsolescence spreadsheet 28
Computerized Maintenance Management System (CMMS) Data Utilize data to increase efficiencies - Call center activity - Remote alert monitoring activity - CMMS reports Case studies 29
Advanced Metrics and Scorecards Key Performance Indicators (KPI) - Uptime - Preventative vs. Reactive maintenance - Meantime Between Failure (MTBF) - Meantime to Repair (MTTR) - Maintenance Costs (Parts and Labor) - Manpower Efficiency Example KPI report 30
Key Takeaways Importance of auditing your system and programs Areas to focus the auditing effort Methods of auditing Tools that make audits more effective Setting standards and keeping score 31 31
Conference Cloud Additional Resources How to maintain your conveyor system like a pro - http://www.manufacturing.net/articles/2013/01/how-tomaintain-your-conveyor-system-like-a-pro Does you conveyor need a tune-up? - /http://www.dcvelocity.com/articles/20110613conveyor_t une_up Key points to keep in mind when conducting a software audit - https://iaonline.theiia.org/key-points-to-keep-in-mindwhen-conducting-a-software-audit 32 32
Conference Cloud Additional Resources White Paper 2015 MATERIAL HANDLING & LOGISTICS CONFERENCE SPONSORED BY DEMATIC MHLC. COM 33
Questions 34
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