PROCESS ANALYSIS TRAINING MAINTENANCE

TASKS ANALYSIS

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 Welcome!

Safety Orientations

Cellphones and laptops

Time: Beginning, end, breaks

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1 OBJECTIVE, TARGET AND PRE-REQUIREMENT

Training Objective
Disseminar o mtodo de considerar, na Anlise Integrada de Processos, as tarefas realizadas pelo
mantenedores das reas de produo.

Target Audience:
Leadership (Managers and Leaders) of Production and Maintenance in our analysis process,
Responsible of the 5 quality dimensions (Health and Safety, Environment, Quality, Costs and Deliver)
and Management System that support the process and maintainers.

Pre-requirements:
Module 2 MS (Process Analysis)
GG10-01-OI (Usage of the Task Risk Determination Matrix 5X5 Matrix)

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2 PROCESS ANALYSIS BASIS FOR THE QUALITY PLANE

CONCEPTS REVISION:
Process: Collection of ordered and connected steps, with beginning and end defined, that aggregate value to
the products and services delivered, attending the requirement of the Stakeholders.
Process Step: Task collections, with product, supplier and client identified.
Task: Distinctive activities collection, in sequence and connected, that has the objective of producing a
specific result.
Activity : The smallest subdivision in a tasks execution.
RETURN

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3 BUSINESS DEFINITION

The Business Definition in the maintenance cells of the production areas must follow the previewed in the
MS Module 2 Process Analysis.
The Business exists for the attendance of the Stakeholders needs. In the Maitenance Case, the
Production is mandatorily one of the Stakeholders.

Authority Accountability

Exist to fulfill the needs of the

GOALS
Inputs
Suppliers

Business Products Stakeholders

x x

x KPI

Critical Parameters
e
n sur
e
CIs CIs

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Example
MAINTENANCE
SUPPLIERS INPUTS PRODUCT/SERVICES CLIENTS

le
op
MAINTENANCE PRODUCTION
SAAE WATER

Pe
SERVICES AREA

ELETRIC ENERGY - Operational and Administrative SUPPORT

BANDEIRANTES - Leaders IMPROVEMENTS
AREA

PLANNED MAINTENANCE
PIECES - Preventive Maintenance, SPARE PARTS
WAREHOUSE - Predictive Maintenance,
- Programmed Corrective Maintenance
EQUIPMENTS UTILITIES
3
AUTONOMOUS MAINTENANCE
ENGINEERING AND INFRAESTRUCTURE
IMPROVEMENT AND TECHNOLOGY - Initial Cleaning,
- Combat to the locals with difficult
- access and dirty places,
- Revision and standardization,
- Training for general inspection,
- Autonomous Inspection,
- Organization and Managing of the
VERIFICATION ITEMS - work place KPIS
- Autonomous Planning Control
- Refuse to Risky task - Total Accidents (WLTA, Property Damage and LTA)
- Number of reports 5 - Environmental conformity index
- Control and Monitoring of wastes - Productivity
- water consumptions and generation of liquid effluents MAJOR REFORMS CONTROL - - Maintenance Interruption
monitoring - Fixed Cost for Maintenance
- Area Security evaluation
- Planning and big stops control - Variable Cost for Maintenance
- Attendance to the General Inspection panned
- Stops program
- QL overtime
- Stops planning
- Performance Evaluation
- Coordination and accompaniment of the
- Training Matrix Attendance
- stops
- Maintenance FA
- Planning and evaluation meetings
- Attendance to the Maintenance Plans
- Monthly Environment Evaluation 1
- Attendance to the Autonomous Maintenance Checklist
- Attendance to the Autonomous Maintenance Auditing
- Attendance to the training matrix DATA MANAGEMENT
- Inputs consumption in STAR
- Pieces and services consumption
- Urgent purchases
- Technical Documentation,
- Maintenance Data Base (SAP PM)
- Maintenance KPIs Managing

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Example

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4 PROCESS MAP

Its not necessary to criate a Process Map for the Maintenance Cell of the production areas. The
maintenance taks, as will be seen in the following slides, must be incorporated to the Productive Process
Map that is attends.

PROCESS MAP OF THE DRAWING MAINTENANCE

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5 MAINTENANCE TASKS ANALYSIS
The objective of the Maintenance Tasks Analysis, inside of the Process Analysis, is to know and to treat the
critical points of these tasks, aiming the Process Stabilization where they will be executed.
For this, the following steps will be executed:

1 Know the critical parameters of the process

2 List the maintenance tasks relevant for these parameters

3 Identify which one of these tasks are critical

4 Deploy the critical tasks into activities

5 Identify the critical activities

6 Identify the potential losses in the critical activities

7 Treat the critical task and activities

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5.1 Know the critical parameters of the process

1 Know the critical parameters of the process

2 List the maintenance tasks relevant for these parameters

3 Identify which one of these tasks are critical

4 Deploy the critical tasks into activities

5 Identify the critical activities

6 Identify the potential losses in the critical activities

7 Treat the critical task and activities

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5.1 Know the critical parameters of the process

The Critical Tasks Analysis work in maintenance, starts from the Critical Parameters of the production
process.

Critical Parameter of the process is that one that has high impact over the products parameter
(processing or finished) in the process that is being analyzed, or in the subsequent products. The definition
of the Critical Parameters must follow the MS Module 2 Process Analysis.

PROCESS Process A

PROCESS STEP Step 1 Step 2 Step 3 Step 4

PROCESS X1 : X1 : X1 : X1 :
PARAMETERS X2 : X2 : X2 : X2 :
X2 : X2 : X2 : X2 :
... ... ... ...

The process parameters are associated to the respective steps of the process and are normally designed for
the letter (x). The critical parameters of the process are highlighted in relation to the others with the symbol
(*).

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5.2 List the maintenance tasks relevant for these parameters

1 Know the critical parameters of the process

2 List the maintenance tasks relevant for these parameters

3 Identify which one of these tasks are critical

4 Deploy the critical tasks into activities

5 Identify the critical activities

6 Identify the potential losses in the critical activities

7 Treat the critical task and activities

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5.2 List the maintenance tasks relevant for these parameters

The question to be answered is: Which one of the Maintenance Tasks are relevant for the critical
parameters of production?
These tasks must be incorporated to the Process Map, in the respective step, and classified in Routine
or Extra Routine, according to MS Module 2 Process Analysis.

Alignment of the maintenance tasks with the Process Analysis :

Routine Tasks:
- Inspections (preventives, perfectives, etc)
- Component changes based on time/number of operations
- Lubrication tasks planned

Extra Routine Task:

- Anomalies removal due to inspections
- Repairs due to breaks

Observations:
1 - By Relevant, understand all of that, according to the Maintenance team evaluation, has the chance to
become a critical task.
2 The concept of Auxiliary Task does not apply to the maintenance tasks.

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Example

PROCESS Casting

PROCESS STEPS Machine Start

PROCESS X Air pressure in the long tube (C*)

PARAMETERS 1

* => Critical X Water leak in the mold (C*)

2

-R: Visual Inspection of the leak system in the long tube

- R: Calibration of the pressure switch in long tube - Preventive
1 Instrumentation
- ER: Pressure Switch change Emergency correction

R = Routine R: Inspection at the transmitter and flow sensor

TASKS

ER = Extra R: Inspection in servo motor control flow

Routine R: Inspection of the operation of water pumps - Ronda Godfather Mechanic
R: Maintenance of vertical pumps - Preventive Mechanics
2 ER: Replacing the control valve against pressure flow system Argon long tube
- Corrective Emergency / Planned
ER: Replacing the rotor of water pump - Corrective Emergency
ER: Alignment of the motor-pump - Corrective Emergency / Planned
ER: Reform of vertical pump Central Office - Planned Corrective

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Example

PROCESS Rolling Mill

PROCESS STEP Finishing Train

PROCESS X1 - Pressure / flow of water in the cooling zone (C *)

PARAMETERS X2 - Traction Bars cages between M1 and M2 (C *)
* => Crtical

R: Preventive pumps water cooling zone

R: Cleaning the boxes in the area of return
R: Check the filter differential pressure of the water system (filter saturation) -
1 Ronda Godfather Mechanic
ER: Changing the filters - Planned
ER: Replacing valves water pressure - Emergency / Planned
-ER: Reform of Booster pumps - Maintenance External
R = Routine
TASKS

ER = Extra
Routine R: Setting the twist cages between M1 and M2 - Electrical Preventive
R: Lubrication lace M2 (Articulation and Rollers) - Preventive Lubrication
R: Maintaining the pulse generator of electric motors M1 - Preventive
2 Instrumentation
R: Maintaining the pulse generator of electric motors M2 - Preventive
Instrumentation
ER: Changing the pulse generator - Corrective Emergency
ER: Exchange Roller lace - Emergency / Planned

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5.3 Identify which one of these tasks are critical

1 Know the critical parameters of the process

2 List the maintenance tasks relevant for these parameters

3 Identify which one of these tasks are critical

4 Deploy the critical tasks into activities

5 Identify the critical activities

6 Identify the potential losses in the critical activities

7 Treat the critical task and activities

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5.3 Identify which one of these tasks are critical
Once listed, the maintenance tasks relevant to the Critical Parameters of the operation, it is necessary to
identify which one of these tasks are critical .
This identification must be done through the Tasks Risk Determinination Matrix (5x5 Matrix), according to the
instruction GG10-01-OI, that is, the same flow that was already practiced for the other process tasks.

Probability: evaluates the chance of waste

Severity: Measures the greatness or occurrence, considering the following
meaning of the waste occurrence, aspects:
classified in one of the categories: - Events historic/occurrence possibility
( 5 ) Catastrophic - Existing Controls
( 4 ) Critical
( 3 ) Moderated
( 2 ) Marginal
( 1 ) Negligible

Frequency of generation of the

Environmental Aspect in the task
execution: applicable only for the
environment dimension

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5.4 Deploy the critical tasks into activities
5.5 Identify the critical activities

1 Know the critical parameters of the process

2 List the maintenance tasks relevant for these parameters

3 Identify which one of these tasks are critical

4 Deploy the critical tasks into activities

5 Identify the critical activities

6 Identify the potential losses in the critical activities

7 Treat the critical task and activities

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5.4 Deploy the critical tasks into activities
5.5 Identify the critical activities
In general terms, a task in composed by 5 to 10 activities.
The objective of the deployment in the critical task in activities in to clearly see which activities make the
task critical. In the activity level, it is not necessary to use the 5x5 matrix to evaluate which one of them are
critical. Generally, in this detailing level, the team knowledge is enough. The same suggested table can be
used for the other tasks, to do the step 5.3 to 5.6.

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5.6 Identify the potential losses in the critical activities

1 Know the critical parameters of the process

2 List the maintenance tasks relevant for these parameters

3 Identify which one of these tasks are critical

4 Deploy the critical tasks into activities

5 Identify the critical activities

6 Identify the potential losses in the critical activities

7 Treat the critical task and activities

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5.6 Identify the potential losses in the critical activities

Understand what can happen if a Critical Activity is not executed or executed incorrectly.
Evaluate the potential wastes, according to the 5 dimensions:

Health and safety Illness and injuries

Environment Environmental Impact
Quality Non comformity of the product
Costs Costs beyond the planned
Deliver Interruptions and Delays

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5.7 Treat the critical task and activities

1 Know the critical parameters of the process

2 List the maintenance tasks relevant for these parameters

3 Identify which one of these tasks are critical

4 Deploy the critical tasks into activities

5 Identify the critical activities

6 Identify the potential losses in the critical activities

7 Treat the critical task and activities

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5.7 Treat the critical task and activities
Actions must be elaborated for the treatment of critical activities, wiling to eliminate the task, make it to stop
being critical or standardize.
1st: Eliminate the task or its critical activities
- Can the task/activity be eliminated?
2nd: Reduce the criticality
- The critical activity can be combined with others?
- The critical activity can be reorganized inside the task?
- The critical activity can be simplified or reduced?
- Something in the critical activity can be replaced?
- The critical task or activity can be replaced in somewhere else?
3rd: Standardize

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5.7 Treat the critical task and activities
- The remaining tasks of maintenance, that doesnt deploy processes critical parameters, must have its
criticality , according to the Safety dimension, analyzed and treated according to the item described in
the Practice 4 in the Safety GBS.
- After defined, the treatment will be done in the tasks and activities that are critical, what concludes the
Process Analysis and the Standardization step will be executed when this treatment starts.

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7 MAINTENANCE CRITICAL TASKS STANDARDIZATION
The standardization aims to ensure that everyone realizes the critical tasks correctly, in a safe way, with
environment protection, quality in the products and serviced, low cost and attendance to the delivery
prompts. For the critical tasks classified in Routine (Inspections), the standardization must be done in the
Maintenance System SAP PM, highlighting the critical tasks and activities (see example).
For the critical tasks that are Extra-Routine (Remove anomalies and breaks), must be used RP (routine
procedures) and/or OS (operational standard), according to each case.

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8 PRACTICAL EVALUATION:

Divide the team in groups up to 4 people.

Selcet any process step, that the team has a good knowledge.
Raise the critical parameters of the process in that step.
List the maintenance tasks related to, at least, one of the critical
parameters.
Analyse the criticality of hese tasks, using the 5X5 Matrix.

TIME OUT
0 min 5 min 10 min 15 min 20 min

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