Your equipment and the operators who run it are indispensable to your operation. However, it is puzzling that these vital assets often receive minimal training and are shuffled around as though they are mere cogs in the machine. This practice not only undermines your continuous improvement efforts but also leads to the misguided belief that your equipment is defective or that your staff lacks competence.
10 Tips to Boost Equipment Reliability with Operators
It is time to change that perspective. Here are ten strategies you can implement right now to boost your equipment reliability:
- Implement Comprehensive Training: Your operators should understand not only the basic operations of their machines but also the underlying mechanics and the standard performance metrics. Insist on structured training rather than the informal, observational methods that are all too common.
- Minimize Equipment Rotation: Constantly switching operators between machines can be as counterproductive as swapping cars between drivers in a NASCAR race. Specialize your operators to enhance their proficiency and safety with specific equipment.
- Engage in Root Cause Analysis (RCA): Effective RCA is crucial. Encourage your lead operators to spearhead this process and dig deeper to identify the true causes of failures rather than settling for superficial explanations.
- Apply Precision to Product Changes: Product change struggles are often caused by a lack of precision. To ensure accuracy and efficiency during changes, incorporate precise methods and tools, such as jigs and templates.
- Participate in Reliability and Maintenance Programs: Get involved in Reliability-Centered Maintenance (RCM) and Total Productive Maintenance (TPM) initiatives. These programs help understand the intended function and maintenance needs of your equipment, enhancing both reliability and operational knowledge.
- Make Data-Driven Decisions: Cultivate a culture where data supports decisions. Teach operators to gather, analyze, and use data to advocate for improvements and changes.
- Elevate Safety Practices: Safety is non-negotiable and integral to equipment reliability. Address and correct unsafe practices immediately and emphasize the importance of following safety protocols.
- Prioritize Cleanliness: It is well-established that clean machines operate more efficiently. Allocate time for operators to clean their equipment and perform routine care tasks during each shift. Define these tasks clearly with detailed descriptions of the cleaning agents, tools, and expected results.
- Master Statistical Process Control (SPC): Encourage operators to learn SPC to understand better when adjustments are necessary based on operational and product parameters. This knowledge transforms operators from passive to proactive participants in the production process.
- Adhere to Checklists: Utilize detailed checklists for starting up and shutting down equipment, ensuring it is fit for use and during product changes. These checklists are vital for maintaining operational discipline and safety.
Understanding the hard work and dedication of equipment operators, especially those working irregular hours, is crucial. By implementing these practices, you will enhance the reliability of your operations and acknowledge and leverage the skills of your operators, who often have insightful contributions to make.
As you continue to champion these changes, remember the value and impact of empathizing with the challenges faced by those on the production floor. These strategies are not just about improving operational efficiency but about fostering a workplace where everyone is recognized for their role in achieving success.
Enhancing overall plant maintenance and reliability hinges not just on the robustness of the equipment but significantly on the empowerment and expertise of the operators managing these machines. The relationship between operator knowledge, machine performance, and proper maintenance is undeniable. Fostering a culture that prioritizes comprehensive training, precise operations, and proactive maintenance practices is crucial.
Allied Reliability recognizes the intricate dynamics of plant operations and the pivotal role that effective maintenance planning plays in the longevity and reliability of equipment. With a deep understanding of industry best practices and maintenance methodologies, we are uniquely positioned to help your facility identify potential inefficiencies in your equipment management and implement tailored, effective solutions.
ABOUT ALLIED RELIABILITY
Allied Reliability provides asset management consulting and predictive maintenance solutions across the lifecycle of your production assets to deliver required throughput at lowest operating cost while managing asset risk. We do this by partnering with our clients, applying our proven asset management methodology, and leveraging decades of practitioner experience across more verticals than any other provider. Our asset management solutions include Consulting & Training, Condition-based Maintenance, Industrial Staffing, Electrical Services, and Machine Reliability.
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