SUPPLY

CHAIN
DEPARMENT
BREAKDOWN REDUCTION

Basic considerations

Breakdowns can be drastically reduced

even without making complex changes to

machines
Most breakdowns, in fact, are generated

by simple causes

Example
Company EFES, Plant Karaganda - Breakdowns
reduction group
Breakdo

wn:
Failed:

extruder
stop
electrical
motor

Sequence of

events:
Seal on
motor
broken

Entry of
grease and
carbon
powder

Breakdown
of
insulation

"Hidden"
anomaly

Earth fault

Motor
failed

Breakdo
wn
Cause
analysis

Example (cont'd)
Actions resulting from analysis
Modification of cleaning and

inspection check list to prevent

excess
motor
grease.

Solid inspection plates replaced with

the ones fitted to allow visual

checking while motor running.

Basic considerations (2)

Breakdowns are caused by hidden anomalies
Anomalies have to be removed instead of

being neglected
Breakdowns
Hidden
anomalies
Dust, soiling, adhesion of raw

materials
Abrasion, looseness, leaks
Corrosion, deformation, cracks
Temperature, vibration,
sound and other errors

Any anomaly is a hidden breakdown: examples

(1)
What
is this
hole?

No
bolt!

Is there
the name
plate?

Are the
limits of
voltage and
current
shown?

Mess
y
wirin
g!

30

Are
four
bolts used
to fix the
dog?

The door
will not
close

Any anomaly is a hidden breakdown: examples

(2)
30

55

Tightening of
the lock
nut!

Is the oil
temperat
ure OK?

Methods to avoid
loosening

Oil
leakage!!
Oil
leaka
ge!

Loosen
ed

It's hard to
check oil
quantity and oil
pressure!

Losses due to poor cleaning

Before

After

Accelerated deterioration

In presence of dirt and untideness, it is dificult to check and

detect loosenings, cracks, clearance, lack of oil, with subsequent
continuous forced deterioration

Losses due to poor cleaning

Defect
Infiltration of foreign bodies in

products and malfunctionings of

equipment
generate defects

Speed loss
Insufficient cleaning increases

resistance to sliding, with

subsequent capacity
reduction, machine
stoppages and speed loss

Losses due to poor cleaning

Breakdowns
The infiltration of foreign bodies in rotating parts, in sliding parts, in
pneumatic and hydraulic systems, in electric and control systems, in
sensors, etc. generates malfunctions and breakdowns , blockage,
resistance and feeding of inadequate power

Fundamental Rule
It is normal for a
machine to
break down!

Toda
y

The way we see breakdowns has to be

changed

We don't let our

machine break
down!

Tomorro
w

Some typical breakdown causes

Design weakness
Lack of preventive

maintenance
Previous quick fix
Incorrect production
operation
Spare part quality
Lack of spare parts

Four levels for breakdowns

management
a. Breakdowns losses
b.Breakdowns types
c.Breakdown/Preventive
maintenance
d. Applied preventive maintenance
techniques
e.Autonomous Management
f. Parts life

a. 1% --> 0%
b.Zero breakdowns
c.Only preventive maintenance
d. Condition-based maintenance
e.Auton. Mngt. activities stable
and refined
a. 5% --> 1%
f. Life span predicted
b. Chronic and some sporadic breakdowns
c. Mostly preventive maintenance
d.Time-based maintenance
e.Autonomous Management activities well
established
f. Life span stable and being lenghtened
a. 10% --> 5%
b. Sporadic and chronic breakdowns
c. Some preventive maintenance
activities
d. Some daily maintenance
activities
a. ---> 10%
e.Autonomous Management being
b.Repetitive
organized
c.Breakdown maintenance
f. Lifealmost
span measured but unstable
exclusive
d. None (only breakdown maintenance)
e.No Autonomous Management
activities
f. Parts life span, although measured,
but unstable

Exercise: At what level are we now?

Breakdowns/Preve
ntive
maintena
nce

Applied
preventive
maintenance
techniques

Breakdowns
types

Breakdown
losses
1
2
3

Autonomo
us
Managem
ent

Parts
life

Why eliminate breakdowns?

Company
performa
nce
category
P

Impact of
breakdo
wn (*)

Reduce machine
Waste
material, energy equipment and
availability

(Productivi
ty)
Q
(Qualit
y)
C
(Costs
)
D
(Deliver
y)
S
(Safet
y)
M
(Personn
el
Motivatio
n)

Description of
impact
manpower time
Create
defects

Require "fire fighting"

work
Require inventory
downstream
Create delays in
production plans
Create high-risk

situations

the possibility of accidents

increases during repair jobs

Create

dissatisfaction

(*
)

=
High

=
Medium

=
Low

The Route for breakdown reduction: the

activities
1. Summarise
5
4
3
2
1

Define preventive
preventive
Define
maintenance
maintenance
plans
plans
Highlight the
the
Highlight
causes of
of
causes
sporadic
sporadic
breakdowns
breakdowns
Attack repetitive
Attack
repetitive
breakdowns
breakdowns
Restore basic
basic
Restore
condition in
in critical
critical
condition
areas and
and set
set standards
standards
areas
Identify breakdown types
Identify breakdown
types

causes &
breakdown
analysis
countermeasures
2.Implement
from
actions and
countermeasures
syste
3.Set the planned
4. m
Set the Machine
maintenance
Board

1. On the important areas,

define the failure modes
2. Carry out 5why
failureon
modes
analysis
3. Define
4. Implement
countermeasures
5.
Establish a monitoring
countermeasures
system for reoccurrences

1. Set up a data collection

system
2. Analyse historical
data & set
performance
indicators
3. Deploy breakdowns and
carry out a Pareto

1. Introduce
a
new
breakdown
definition
to improve the data
collection system
2. Introduce the breakdown
3. Define the system to
analysi s sheet
support it
4. Train all the relevant
operators and
maintenance technicians
5. Implement the system &
continuously follow up
2. analyses
Perform Initial
and results
Cleaning and Tagging
1.
areas
3. Identify
Manage critical
the
4. Define and Implement
Tags
Cleaning, Inspection and
Lubrication standards
5. Restore all the
Operating
Standards

Step 1 for breakdown reduction:

summary
The
Activities
1

Identify breakdown types

Identify breakdown
types

1. Set up a data collection

system
2.Analyse historical data
and set performance
indicators
3.Deploy B/Ds and carry out a
Pareto Analysis

Set-up a data collection system

Date/sh
ift

Produc
t.
Operat
or

Mainte
n.
Techni breakdo
c.
wn

Tim
e
machi
interventi
ne
on

machi
resta
ne
rt

Compone
nt faile
d

Failur
emod
e

Fixin
g
interventi
on

Long
term
countermeas
ure

Deploy breakdowns by sections,

subassemblies &
compone
nts

Number of breakdowns FILLER

Num ber of breakdowns TOT AL

Com p.
2

4
2

Filler

Com p.
4

10

1
5

20

15

Comp .
1
2
0

30

4
0

50

Comp .
2
13

Comp .
3

Source: 20
weeks

1
0

Number
of breakdowns 6
PACKER

2
0

Palletiz
er

2
0

Labelle
r

10

Com p.
3

3
8

Packer

20

Com p.
1

Comp .
4
8 5

1
0

1
5

25

Step 3 for breakdown reduction:

summary
The Activities

Attack repetitive
Attack
repetitive
breakdowns
breakdowns

1.On the important areas,

define the failure modes
2.Carry out 5-why analysis on the
failure modes
3.Define the countermeasures
4. Implement the
countermeasures
5. Establish a monitoring
system for the reoccurrences

On the important areas, define the

failure modes
Number of breakdowns FILLER
Comp.
1

Failure
Modes ?

2
0

Comp.
2

1
0

Comp.
3

Comp.
4

6
0

1
0

1
5

2
0

2
5

Failure modes & root

causes An example
Examples of failure
modes
Impeller worn out
Impeller falls of
Impeller

smashed by a
foreign body

Failure modes & root

causes An example (2)

The root causes

are
Impeller worn out:

lack of preventive
maintenance:
changing impeller
before end of
useful life was not
considered
Impeller falls of

human error: some

operators are not able
to fit impeller correctly
impeller smashed:
design fault: no
protective screens
have been provided

Carry out 5-why analysis on the

failure
Patternmodes
mend
reduction

4th
why

1.1.1.1 Too
Pattern mend 1. Heald wires 1.1 Too much 1.1.1 Heald
wires
Problem broke on
1stwide
whystress on
2nd
whylocks and
3rdbreaksmuch
required
the
in vibration
central
loom
wires
the heald
why
in the
zone
(mainly in
frames
the
cente
r)

1.2 Heald wires in 1.2.1

bad condition on checked
Wires
not
the loom
before
knotting

1.2.1.1
not
Knotters
trained
1.2.1.2. May
not be part
spe
of job
c.

5th
why

1.1.1.1.1 No
wide
heald
support
for
frames

Actio
n

1.1.1.1.1
all the
Resetting
frames
according to
design
the
specs

1.2.1.1
Retrain
knotte
rs
1.2.1.2. Check
job
specif., add
one and
new
train
knotters

Owne
r

Plann
ed

JT/
PW

JP7/
W1

MH

P6W
4

MH

P6W
4

One Point Lesson - Pattern mend project

Heald
frame

Befor
e

No central
support

Problem:
On wide looms, there is
greater vibration and
stresses experienced on the
heald frame. This sometimes
causes a heald wire to break
which, in turn, may require
pattern mend.

Solution:
By fitting a central support to
the frame, vibrations are
greatly reduced and the
number of pattern mend also
reduced.

Heald
frame

Afte
r

With central
support

Implement the countermeasures: the

action plan from the 5 why analysis
Anoma ly
A AA

5W
Ye s

Acti on
n.
1

Acti on desc ri pti on

xxxxxxxxx

Ow
ner
WS

Expected
date
May 31

xxxxxxxxx

MG

May 31

xxxxxxxxx

LS

June 10

xxxxxxxxx

LS

June 10

5
6

xxxxxxxxx
xxxxxxxxx

WS
LS

May 31
June 10

Actual date
Jun 10
e
Jun 10
e
Jun 10
e
Jun 10
e
May31
Jun 10
e

Step 4 for breakdown reduction:

summary
The Activities

Highlight the
the causes
causes of
of
Highlight
sporadic
sporadic
breakdowns
breakdowns

1. Introduce a new breakdown

definition to improve the data
collection system
2. Introduce the breakdown
3. analysis
Define the
system to
sheet
support it
4. Train all the relevant
operators and maintenance
technicians
5. Implement the system &
continuously follow up
analyses and results

Introduce a new breakdown definition to

improve the
data collection system: Measuring MTBF
and MTTR
MTBF
The system's
MTTR
ability to
perform
without
breakdowns

The
The system's
system's
ability
ability to
to be
be
restored
restored and
and
maintained
maintained in
in
its
its
operatio
nal
condition
conditio
s
ns

Introduce the breakdown

analysis sheet What is it?

It is a simple tool to support the analysis of

every single breakdown

Breakdown analysis sheet:

example
Mac hi Elect.
Mo to r
ne
01/01/08
Dat
1
e
Shi
What happened and where
ft c arbon bla ck were found in
Grease
and
(sec tion/subassembly)

Time of
breakdown Time
of intervention
Time to repair
Time to start-up

11.04
12.23
3 hours

Production
Operat.
M aintenance
Techn.
Team

16.00

Sketc
h

the moto r A major leak occurred in the

main shaft bearings

Prior signs before the

Speed
breakdown

Stat
or

loss
Vibratio
n Greaseof
Descr.
lea k

Air
cooling

Green
White
Yellow

Insulatio n
covered by
grease and
carbon black

the repair interv. (specify component you have

worked on) + spare parts used
Insulation on brush bar cleaned a nd ba sic conditions resto red
(insulatio n level) Carbo n black removed fro m moto r

Failure mode + sketch (use the back of

the sheet)

Roto
r

Brush bar broke and motor was stopped as a direct co nsequence

Use the back of the sheet for 5 why analysis on the failure mode identified (Operator +
Maintenance Technician)
Roo t causes
"Earthing" failure o n brush bar

Cat.(*)
2

"Earthing" failure o n brush bar

Were checks already planned to prevent

Description
this failure?
General inspection

Are new checks required/actions required to totally eradicate

Description
breakdo wns?
Wet seal bearings set up

Filters' set up for the cooling pla nt

Inspections standar d fo r electrical engines filters' co nditio ns

Grease leaks from

bearing

Countermeasures
Install a filter a nd ma ke preventive checks (every
week)
Repla ce bearing with a leak-proo f one

By whom
Electrical
technicians

Frequency
Monthly during the PM shutdown

By whom
Electrical
technicians
Electrical
technicians
Electrical
technicians

Frequency/long term a ctio n

Monthly during the PM shutdown
Monthly during the PM shutdown
Monthly during the PM shutdown

(*) 1. Design faul ts 2. Lack of preventive maint. 3. Previous quick fix 4. Incorrect prod. operation 5.
Spare part quality/availabilit y

Breakdown Analysis Sheet

What is it for?
The lack of deep analysis on breakdown causes

is often the reason why no efective

countermeasures are taken to prevent
recurrence
Breakdown reports are too often filled in

quickly, not recorded or not used to decide

proper countermeasures.
There are a lot of things we can learn from a

breakdown
Understanding

breakdown causes allows us to

learn how to prevent its recurrence also on other
similar components or machines.

Introduce the breakdown analysis sheet

Information to be collected for every
breakdown
Time of breakdown, time for intervention, time to repair,

time to start the machine up, production operator,

maintenance technician(s)
What happened & prior signs before the breakdown
Which component failed, in which subassembly, in which
section
What is the failure mode (a sketch must be included)
What has been done to restart the machine (fix
intervention) and spare parts used
What are the root causes (5 why analysis) and of which
type (design fault, lack of preventive maintenance, ...)
What are the countermeasures to avoid/prevent the
breakdown in the future, how they are integrated with
the already existing preventive actions

The breakdown analysis sheet

7

1
3
4

Ma
Ti m e o f breakdo wn
chi ne
Da
Ti m e o f int ervent i on
te
Shi
Ti me t o repa ir
Wha t ha ppened
and wh ere ( sect io
ft
n/subassem bl y)
Ti me to start
-up

Pro ducti o n Operat .

Mai nt enanc e Techn .

Sketc
h

Te am

Pri o r si g ns b efo re the brea

kdow n
D escr. of the repa ir i nterv . (speci fy c om pone nt yo u
hav e wo rk ed o n) + spare part s used

Fa i lure m ode + sketc h ( use the bac k of

the sheet )

Use the ba ck o f the she et for 5 why a nal y si s o n the fai l ure mo de ide nti f ied ( Operato r + M
ai ntena nc e T echni c ia n)
Ro ot c a us es

Were c hecks a lrea dy pl a nned to prev ent

D esc r iptio n
this fa il ure?

C a t .(*)

C ou ntermea s ur es

B y wh om

Freq uen c y

A re new c hecks requi red/ac ti ons requi red to to ta ll y eradi ca

D esc r iptio n
B y wh om
te brea kdow ns?

Freq uen c y /l on g term a c t io n

( *) 1. Desi g n fa ul ts 2. La ck o f pre ventiv e mai nt . 3. Prev io us qui ck f i x 4. Inco rrect pro d. ope ra ti o n 5.
Spare part qual i ty /a va i l abi l it y

Breakdown analysis sheet

Electric motor breakdown

Breakdown analysis sheet

Description of what happened

Ba
The extruder
d stops

The electrical motor failed

Goo
The electrical
d motor failed

The brush bar was broken

I found grease and
carbon black inside
the motor
The bearings of the
main shaft lost a lot
of grease

Breakdown analysis sheet"

Understanding how it happened: sketch
Very
bad

Ba
d

Goo
d

Air
cooling

Insulation
coveredand
grease
by carbon
black

Stat
or

NO
SKETCH
Roto
r

Leaks of grease
beari
from
ng

(This means that an

efort was made to
understand what
happened)

It is essential to draw sketches

A sketch is by far the best
communication
It containstool:
all and only the
information
required
Its content is immediately
conveyed to
everyo
ne
Electric
failu
motor
re

the brush b ar throu gh the

Electric
failu
motor
re

Roto
r

Roto
r

Grease leaks
bearin
from
gs

The first sketch

appears, including a
few remarks, but it
is still incomplete.
GOaON
LIKE THAT
!
Somebody starts to make
simple,
tentative
sketch
STILL IMPOSSIBLE TO UNDERSTAND !

Stat
or

Electric
failu
motor
Cooling
re
air

air cooling
bar
system
Stat
or

Electric
failu
motor
re

NO
SKETCH

Electric motor
Carb
on black entering on Broken
failure
brush

Grease
fr om
leaks
bearings

FINALLY, well-done
sketches are produced:
Complete, essential,
containing all remarks
needed
to understand
VERY
what
GOOD !
happened!

After repeated requests, a technical drawing taken from a Supplier or from the
Technical Office is shyly produced: you understand a little more, but it is still not
enough.
GO BEYOND !
At the beginning, nobody dares to draw a sketch: people are ashamed of not
being good at drawing. OVERCOME THIS PHASE IMMEDIATELY!

Insulati
covered
on
with
grease
carbon
an d
black

Breakdown analysis sheet

Were there any warning signs?
Were there any symptoms before the machine

broke down?

Vibration
Oil leaks
Noise

Does this breakdown type include early symptoms

of any sort?

Yes
No

Breakdown analysis sheet Were there

any warning
Which symptom can anticipate a breakdown?
signs?

Speed loss
Defects
Noise
.....

Why is not it possible to identify breakdowns early

based on their symptoms?

Breakdown symptoms are not known

Measuring units are unknown

What should be done to identify symptoms?

What sort of progressive or predictive maintenance

will have to be implemented?
What more should operators know and be skilled at

in order to identify early symptoms?

Breakdown analysis sheet

Repair description

Ba
I repaired the
d motor by

replacing the brush bar

Goo
Bearing replaced
d

Brush bar replaced

Brush bar insulation cleaned and basic
conditions restored (insulating layer)
Carbon black removed from motor

Breakdown analysis sheet

Five why analysis
Bad
Problem
Why 2

Why
3

Why 1

Why
4

bar replacement
bar
replacement
every 66 months
months
every

The motor broke 1. Brush bar broke

1.1
End of brush bar down
down
lifecycle
2. Bearing
Bearing
2.1 Grease
Grease leaks
2.
2.1
jammed
jammed
leaks

Goo
Proble
d
Them
motor
stopp
ed

Why
1

1.
Ground
breakdown
brush
on
bar

Actions
Action
s brush
Preventive
brush
Preventive

Preventive
Preventive
replacement every
every
replacement
3
months.
3 months.

Why
2
1.1 Insulation

Why
3 black on
1.1.1 Carbon

Why
4
1.1.1.1 No

Actions
Action
s
Filter replacement
replacement
Filter

loss

brush
bar through air cooling
system

filter

and preventive
and
preventive
check
check (weekly)
(weekly)

1.1.2 Grease
Grease leak
leak from
from
1.1.2
main bearing
main
beari
ng

1.1.2.1 Bearing
Bearing
1.1.2.1
is not
not leakproof
is
leakpro
of

Bearing replaced
replaced
Bearing
with aa leakproof
with
leakproof
one
one

Breakdown analysis sheet"

What can be done to eradicate a breakdown?

Ba
No suggestions
d

Goo
Install leak-proof
d bearings (dry bearings)
Install air cooling filters
Electric motor filter inspection standard

The "Breakdown Analysis Sheet"

Basic questions for breakdown analysis
Why did the equipment

break ?
Why did that specific

component break?
What about the stress
applied on that
component?
Why was that stress
applied on that
component?
What are the

requirements to prevent
this breakdown?
Who takes the
responsibility of the
above said breakdown
prevention? When? How?

Was there any symptom

before the breakdown

occurrence?
Does the breakdown
show any visible
symptom?
Through which symptom
can we make a
breakdown prevention?
Can breakdowns be

prevented through
symptomatic analysis?
How can symptoms be
identified?
What kind of skills and
abilities are required the
operator to identify the
event?

The "Breakdown Analysis Sheet"

Basic questions for breakdown analysis
In case of internal wear:
Did any anomaly occur before the breakdown

appearance?
Is this breakdown mode usually linked to these
anomalies?
Why in this case weren't any breakdowns detected?
Which is the simplest way to pay attention to
symptoms?
Which knowledge and skills enable the operator to

understand the predictive breakdown symptoms?

Tips to fill a "Breakdown Analysis Sheet

Main questions
Breakdown type

Electric
Mechanic
..

Intervention type

Replacement
Restoration
..

Time required for

restoration

Tips to fill a "Breakdown Analysis Sheet"

Why did it happen?
Why did the breakdown

happen?

Which part was injured?

Why did this part break?

In which way did it break?

Piece resistance reduction?

What kind of constraint was

applied on that part?

Mechanic
Electric
Corrosion
Vibration

Why did the constraint occur?

Another component breakdown
Overload
What can be done not to repeat

it?

Which maintenance policies can be

adopted?

Who is in charge of these

activities?

The maintenance operator

The production operator
The technician

Tips to fill a "Breakdown Analysis Sheet"

Examples of failure
modes ...
Impeller worn out
Impeller falls of
Impeller

smashed by a
foreign body

Tips to fill a "Breakdown Analysis Sheet"

Has any predictive signal been identified?
Were bad running symptoms evident before the

machine failure?

Vibration
Oil leakage
..

Does the breakdown mode have early symptoms?

Yes
No

Tips to fill a "Breakdown Analysis Sheet"

Has any predictive signal been identified?
Which symptom can anticipate a breakdown?

Speed losses
Defects
Noise
..

Why cannot a breakdown be early identified through its

symptoms?

Breakdown symptoms are unknown

The measure is unknown

What can be done to identify symptoms?

What kind of progressive or predictive maintenance should be

implemented?

What further kind of knowledge and competence should

the operator have to identify early symptoms?

Tips to fill a "Breakdown Analysis Sheet"

The root causes are ...

Impeller worn out:

Impeller falls of

lack of preventive
maintenance: changing
impeller before end of
useful life was not
considered
human error: some
operators are not able
to fit impeller correctly

impeller smashed:

design fault: no
protective screens
have been provided

Tips to fill a "Breakdown Analysis Sheet

Countermeasures
Root cause

Countermeasure

Design fault

Design modification

Lack of preventive maint.

Quick fix
Incorrect production operation
Spare part quality / Lack of spare
parts

Preventive maint. activities

Maintenance training
Production training
Improved spare part management
system

Tips to fill a "Breakdown Analysis Sheet"

Has a planned maintenance operation to prevent
breakdown been identified?
What is the best planned maintenance task?
The failure mode is due to weakness of components

related?

Scheduled discard task (plan replacement)

Has the failure mode early signs?

Scheduled on condition task (condition monitoring)

Is the failure mode due to absence of machine basic

conditions?

Autonomous maintenance activities

Is there a method/parameter measurable to carry out

an equipment diagnosis?

Predictive maintenance

Tips to fill a "Breakdown Analysis Sheet"

N
1

Reasons for interventions

Suggested actions

Low breakdown repair quality for

operator training lack, or bad work
quality

Train maintenance and

operators, in other words
carry out One Point
Lessons

Insuficient documentation. No records

for M/C, specifics, changeover, etc.

Low breakdown reparation quality

caused by training lack of production
operators: operating errors, no
observance of specifics during
operative proceedings, etc.

Improve record and make

them available to
everybody
Train production people,
etc.

M/C out of specifics, M/C restoration

according to specifics

Train operators and

maintenance people

Bds in M/C design phase (moreover

repetitive ones) caused by M/C
design errors. Even if the M/C is
defined according to the specifics
No breakdown following to previous
restorations on defective parts

Machine re-design

6
7

Make certain that spare

parts are known, recorded,
available and used

There are no preventive maintenance

Define AM and/or PM
actions able to prevent breakdowns
controls
through PM controls, correct lubrication,
restoration scheduling

Breakdown mode

Wear part

Adhesive part

3
4
5

Jammed part
Broken part
Loosened part

6
7
8
9
10
11

Fold part

12
13
14
15
16

Broken wire

17

Electric component breakdown

Steam leakage
Water leakage
Air leakage
Oil leakage
Machine contact or weak electric

Loosened wire
Overload
Insuficient insulation
Burn-out

Define the system to

support it Define a
procedure: An example
N.
1

3
4
5

Step of defect analysis

Breakdown general
data, what
happened, prior
signs
Component failed, failure
mode, fix intervention,
spare parts

Who
Operator

Maintenance Technician
& Operator

Root cause analysis (5 why's) Maintenance Technician

& Operator
Countermeasure
identification
and plan
Implementation and follow
-up

When
At the time of breakdown

After restarting the

machine

Team

1st draft immediately

Reviewed by team within
24 hours
ASAP, maximum 1 week

Team

Daily

Train all the relevant operators and maintenance

The training radar chart on
technicians
breakdown analysis
Defe
ct
descr 5
.

4
3
2

Count. followup

Nam
e:
Job:
Date:
Asse
ssors
:
Train
er:

Dave Ford
Mainten.
operator Nov
20, 1996
XX
YY
ZZ
John Smith

Coun
t.
plann

Befor
e
traini
ng

After
traini
ng

Fix
interventi
on

5Why
Analy
sis
Targ
et

Train all relevant operators and maintenance

technicians Carry out the necessary training:
steps
Identify the link between training needs and the
company/department targets and define the
performance indicator(s)
Identification of the skills and quantification of the
level required

Development of the evaluation check list

Selection and training of the assessors

Carry out an initial evaluation, understand the

gap between actual and required

Prepare training program
Prepare the training material
Carry out the training
Evaluate results (skill level & performance
indicator)

Repeat the training on the weak points

Train all relevant operators and maintenance

technicians The five skill levels and the training
required
Level description
Skill score
Type of training
He doesn't know the
theory
He's not
informed

He knows the
He s
theory
informed

He can do it in practice, in
working
standard
conditions
He can do it very well, also
in non
standard working
condition
He can teach / coach other
people

3
4
5

Classroom
Courses
General
Information
On the job
training
Advanced
training
(on
potential
problems)
How to train people
course

Train all relevant operators and maintenance

technicians The target training levels: An
example
N.
N
.
1
1
2
2
3
3
4
4
5
5

Step of
Step of
defect
defect
analysis
analysis
Breakdown general

Breakdown
general
data, what
data,
what prior
happened,
happened,
prior
signs failed,
Component
failure
signs failed, failure
Component
mode, fix intervention,
mode,
fix intervention,
spare parts
spare parts
Root cause analysis (5
Root cause analysis (5
why's)
why's)
Countermeasure
Countermeasure
identification
identification
and plan
plan
and
Implementation
and follow
Implementation
and
-up
follow -up

Production
operator
Production
operator
3
3

Maintenance
operator
Maintenance
operator
3
3

2
3

4
4

3
3

4
4

2
3

4
4

3
3

4
4

Implement the system & continuously follow

up analyses and results: Have a chart showing
results
5
4
Numb
er

3
2
1
0

1st
week
Occ urred bre ak
downs
An al ysi s wi th
c/meas. im pl.

2nd
week

3rd
week

C ompl eted
analysis
A na lysis with c /me as. i
nef fe ct .

4th
week
An al ysi s wi th c /me as. i
den tif .

Step 5 for breakdown reduction:

summary
The
Activities

Define preventive
preventive
Define
maintenance
maintenance
plans
plans

1. Summarise causes &

countermeasures from
breakdown analysis
2. Implement actions and
countermeasures
3. Set up the planned
maintenance system
4. Set up the Machine Board

3
Root
Cause

2
Compone
nt

1
Failu
re

Have a one page summary of

breakdowns, causes,
countermeasures

4
Countermeasu
res

For each root causes type, the relevant

countermeasure
Root cause

Countermeasure

Design fault

Design modification

Lack of preventive maint.

Preventive maint.

Quick fix

activities

Incorrect production
operation Spare part quality /
Lack of spare parts

Maintenance training
Production training
Improved spare part
management system

Set the planned maintenance

system
High visibility preventive
Planned
maintenance system
10
11
Maintenance
1

19
21

20

37

38

22

39
4

40

23
27

24

1 42
53

25

26

28

43

44

12

13

14

Why this system?

45 46

15

16

17

18

cheap
easy
access
introduction
easy modification &
improvement
29 30
limited
visibility 32 33 34 35 36
bureaucracywith parts
connection
performance and life.

47

48

49

50

51

52

Set the machine board

At the end of Step 5 the team must be

consolidated and the project board turns into
the Machine board: a simple system to hold
the gains