Tip 3: Use data to your advantage
Ideally, you would gather data from all your IT/ OT systems and make them available in one dashboard or KPI overview so everyone uses the same data in the same way. An asset manager or maintenance manager, the roles that usually get assigned to this, usually realize quickly that this is a Herculean task.
Do not panic, you do not immediately need to be an APM 4.0 or Digital Transformation expert. Just start with connecting two systems, preferably the ones that are most valuable for your OEE KPI. Be aware of which data indicates what, whether the data is clean and usable and focus on the data that you should use to support the OEE KPI in a dashboard. Do not be afraid to get your colleagues from other departments and disciplines involved or ask an expert for help.
Tip 4: Prioritize and focus
Which assets are critical for good performance and quality? 20-30% of your assets should be prioritized because good production and performance depend on them. There are many practical ways of prioritizing your assets based on the production dependency. Focus on these assets and start to optimize their performance and their maintenance strategies. Close the loop: keep track of the performance of your priority equipment and keep improving the maintenance regime based on feedback of your data and maintenance technicians.
Tip 5: Give preventive maintenance a boost
Preventing failure of your assets (especially your critical ones) is of course essential. This increases the asset lifetime and availability of the asset which leads to a higher performance rate which also decreases the probability of defects and therefore a higher quality overall. Usual suspects of techniques used for preventive maintenance determinations are TPM, FMECA and RCM methodologies. But do not go into these blindly. Start with a basic maintenance regime based on your own knowledge and expertise, OEM advice or libraries from your business or from an external provider. Things to keep in mind:
- Use the risk-based FMECA or RCM methodologies to optimize the existing maintenance regime and find a smart way to apply the results to similar assets in your plant.
- Be aware that the implementation of the preventive maintenance strategies takes at least as much time as the determination of the strategy. This includes creating work instructions, planning maintenance tasks in your EAM, attaching the right materials, scheduling the tasks and instructing the technicians