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Topic: Lubrication and PLCs
Welcome to the 14th issue of our Feed Forward Newsletter; "The Maintenance War Newsletter". This first area of the
newsletter is for introductions and commentary. Remember, the
website has many new items added each month. So please browse
around and find yourself quality maintenance and engineering information.
Online version at www.feedforward.com.au
In line with the theme of this issue, we are giving away a free Bearing
Lubrication Simulation Software CD with any CD order for the entire
month of July. (Limit one free CD per customer.)
We will also have 5 drawings for a free "Pocket
Maintenance Advisor - hard copy" at the end of July. To qualify
you need only make a purchase during the month of July.
Watch our site in July, as several new books will be
released and also three new troubleshooting CBTs that are not only
educational, but a lot of fun. (If you love to troubleshoot as I
I would also like to take this opportunity to tell you about the new
'Kaizen Corner' area of a website by Author - Larry Bush
My personal favorite out of the 8 Kaizen listed so far, is the one
NON-WRAPPING STRETCH WRAP MACHINE" . What an excellent example of
not only the cost of not updating your PLC equipment, but also the cost of
not training your people on the PLC equipment. Working with a PLC without really
understanding what you are doing can cost much downtime. Also typical, the
failure occurs on an off shift, when the OEM is not available. (What really
hurts is when you find support is even more difficult to find because the
OEM for the outdated equipment, is out of business.)
Yes, another example too,
the value of performing a plant wide PLC assessment of your equipment. You
can download this PLC
assessment - free spreadsheet we use to collect vital info on the PLCs
in a facility. (So why not take pro-active action today!)
One reader asks: "We have tube
making lines running 24hrs a day, 5 days a week."
We work our OEE out by the simple formula
(Best Practical Speed per minutes) x 60min x 24hrs x 5days.
If we run nonstop at best speed all week
(unlikely) then we get 100% OEE
find that several factors impinge on our formula:-
Different jobs run at different speeds
2) Sometimes a line is planned to be off for a day
To keep things simple we continue to use our OEE
formula but I do wonder if we should be varying the parameters such as
best line speed and actual running days. The issue is with several lines
this gets very difficult to track. Any thoughts that might help. Regards,
Your answer is definitely, 'Yes'. The primary purpose of OEE is to be a
Benchmark tool to compare Apples to Oranges. :>) Now the above is a
general answer, to do the best you can, my answer would provide a little
more detail. :>)
The secondary goal of using OEE to is to drive one to get the most
value out of company equipment/facility as one can. To better reach this
goal, some of the fortune 500 companies have developed a second
benchmarking measurement tool daubed, 'TEEP'.
Please see http://www.downtimecentral.com/oee_teep.htm
for more detail.
If you have the same equipment running different products which each
product runs at different speed, you want to use OEE to show you what is
your most profitable product. (IE: if equipment is designed to run 30
pieces per minute, and one product requires you to slow equipment to 15
pieces per minute to maintain quality, that product process needs analyzed
to improve speed.)
As a side note, maybe after much study, the speed for the slower
product could not be improved. Then that lower OEE may be a consideration
when pricing that more costly to produce product.
Where TEEP comes into play is that it uses scheduled production time
I noticed you did not mention quality in your original question, but
you being Six sigma, I am sure you intended that quality being used in the
OEE was assumed. :>)
So in summary, I would recommend both OEE (24/7) for equipment
utilization (ROA) and TEEP for weekly benchmark (setting speed factor by
product) for operating efficiency.
My Quote "Nobody runs 100% OEE, because nobody is perfect. There
is always room for improvement."
Also see OEE
analysis for more insight and read "What
is the True Downtime Cost (TDC)?" or download
Hope this helps
What are SOP's, Procedures and Work Instructions?
Reader Kon S. ask "What are the differences between SOP's,
Procedures and Work Instructions?"
SOP's are Standard Operating Procedures. Which are procedures
(written work instructions) that all follow to give more
consistency and control to the process.
"I have seen companies call there documentation work
instructions, other companies call them procedures and other companies
call them SOP's."
Don further replies ...
I believe I will stick with my first opinion. They are all basically
the same and left up to the interpretation of the one's requesting them to
In many cases, "work instructions" may be just a 'How to'
with less focus on standardization by the author. A less formal version of
the SOP. The use of just the word "procedures" being somewhere
in the middle, with "SOP" being the most detailed version with
the most focus on standardization.
You will probably find the more formal (and descriptive) terminology
"SOP" used more in cases where ISO certification and Corporate
guidelines are involved.
Hope this helps
Training and Development with SOP eBook By Mike
Sondalini - Discover how to realize and release the continuous
improvement power of a Standard Operating Procedure (SOP).
The World Wide Web:
You can pick up the news paper or a trade magazine and read the front page
news or cover story of what that establishment feels is a hot topic. The
truth is you may get an impression of what is a hot topic in our industry, but
in actually, the topic decision was biased, paid for, or just one editor's
The internet has some excellent tools for finding out what is truly the hot
topic of focus for our industry, and it will be completely unbiased. Take for
example Overture's "What's most search for" tool. Below are fairly
new topics that are being most searched for by individuals from around the
world in our industry. You might find them informative and interesting.
automotive industry corp
closing general motor plant
And it is always
interesting to know what topic (relevant to our industry) is the 'most search
for' in the basic categories of industrial, engineering and maintenance. This
gives you a sense of what relevant topic mater has the most internet presence.
(law of supply and demand.)
service commercial industrial
Best regards and thanks for being a subscriber to this
Feed Forward Publications
Tel : (573) 547-5630
www.feedforward.com.au teaches your maintenance crew engineering and asset
care knowledge so that they can solve more problems, become more
knowledgeable, make better decisions and your plant runs more reliably!
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