Maintenance Plans and Tasks: Eliminating Non-Value Added Maintenance Activities for Improved...

Maintenance Plans and Tasks:Eliminating Non-Value Added Maintenance

Activities for Improved Reliability

Robert WigginsShowa Denko Carbon, Inc

Maintenance Planning and Scheduling Supervisor

•Robert Wiggins is a graduate of Trident Technical College with a diploma in the Industrial Electrical program and holds a BS degree in Business Administration/Management from Limestone College. •He has over 27+ years experience with Showa Denko Carbon, Inc. (SDKC) and working in industrial maintenance and manufacturing. •Robert joined SDKC in 1984 as a shift electrician. He has served as a maintenance supervisor, planner and planner-scheduler. •Robert currently serves as the maintenance planning and scheduling supervisor and is responsible for managing four maintenance planners, and the maintenance planning and scheduling activities for 37 technicians and numerous contractor services. •Robert is actively involved with updating and creating maintenance items, tasks, and maintenance plans, as part of a reliability effort to establish an SAP database maintenance library for routine and corrective type maintenance activities.

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GLOBAL CAPABILITY

QUALITY SERVICE RELIABILITY

GRAPHITE ELECTRODES

GRANULAR GRAPHITE

FINE CARBONS

MARKET PLACE


Large-Diameter Ultra High Powered Graphite Electrodes used in the Electric Furnace Steelmaking

Industry

GRAPHITE ELECTRODES




•Friction Materials•Lubricants•Conductive Coatings•Carbon & Graphite Shapes

HIGH PERFORMANCE GRAPHITE FOR AUTOMOTIVE & INDUSTRIAL APPLICATIONS

GRANULAR GRAPHITE


GRAPHITE TECHNOLOGIES FOR ADVANCED ENERGY SYSTEMS

•Vapor Grown Carbon Fiber•Shape Controlled Micro Graphite Powder•Impervious Graphite Composite Plate•Ultra Fine Graphite Powder

FINES CARBON

Construction of Ridgeville plant

Shipment of first 24” electrodes


Acquired by Showa Denko KK

PIP plant expansion

ISO9002 registration

KDAC plant expansionOver $100 million sales



1982 1983 1985 1988 1990 1995 1996 1997 2008

Over $200 million sales

2006


CORPORATE HISTORY

•Petroleum Needle Coke

•Binder Pitch

•Iron Oxide

•Stearic Acid

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RAW MATERIALS


•Iron Oxide

Mix

Extrude Bake Impregnate

RebakeGraphitizeMachine

FormulateNeedle Coke StorageScreen

Binder Pitch

Petroleum Pitch


PROCESS OVERVIEW


SAP RELEASE 4.7

Maintenance Plans and Tasks:Eliminating Non-Value Added Maintenance

Activities For Improved Reliability


Maintenance Planning and Scheduling Supervisor

Preventative Maintenance Plans and Tasks:

•Eliminating Waste

•Increasing Value and Reliability


Inspect???

Check???

Verify???

Ensure???


Update Procedures

Combine Tasks

Adjust Frequencies

Change Crew Assignments


Maintenance Frequencies

Poorly Identified

Duplication Of Maintenance

Tasks.

Incorrect Labor &

Craftsmen Identified

Maintenance Tasks

Assigned With No

Procedures

Shutdown Requirements

Not Adequately Identified

Production Equipment Not

Properly Prepared For Service


First Pass To Pick The Low Hanging Fruit:

Review All Maintenance Plans/Task To

Determine The Actual Job Requirement.

Second Pass: Review All Maintenance

Plans/Task Procedures For Duplications. 15-20% Of PM

Tasks Issued To Maintenance

Technicians Are Most Likely

Performed By Operators As Part

Of Their SOP


Change!!!

Replace!!!

Adjust!!!

Document!!!


Review Tasks For Measurement Points

and Adjustments. Make certain This

Information Is Documented In The

PM Text.

Run To Failure: Carrying Critical Spares And Long

Lead Items. Some Equipments May Be More Cost Effective To Allow To Run to Failure Than Spend

Labor on Inspections.Inspecting Belts, Sheaves, Chains,

Sprockets – Versus Periodic

Replacement Based On Mfg Data And Known Failure

Rates


What Do You Expect To Gain From Your Preventative Maintenance Program?

• Safety: Safety And Health Is Priority For People And Equipment

• Visibility: Well Maintained Equipment Looks Good• Availability: Equipment Runs On Demand• Reliability: People – Processes – Equipment• Maintainability: Ease Of Maintenance • Profitability: Low Maintenance Cost Per Production Unit • Sustainability: Provides Improved Maintenance Program For

Future Workforce


•Maintenance Item Descriptions Should State The Expected Outcome Of The Order

•Item Descriptions Should Be Standardized For Consistency

QUALITY SERVICE RELIABILITY•Maintenance Task Operations Should Be Titled To Indicate The Exact Task Assignment

•Tasks Should Be Broken Out By Craft And By Sequence Of Order

•Each Operation Has Correct Estimate Of Labor Required


Equipment Type

Number of

Equipments

Number of

Maintenance

Orders Issued

Man-

hours/

Orders

Total Cost @

$51.00/hr Materials Total

Bake Furnace

Zone Fans @

Quarterly

Inspections 48 384 2 $39,168.00 none $39,168.00

Bake Furnace

Zone Fans @ 2-

Year Belt

Replacements 48 48 7 $17,136.00 $3936.00 $21,072.00

SAVINGS $18,096.00


Equipment Type

Number of

Equipments

Number of

Maintenance

Orders Issued

Man-

hours/

Orders

Total Cost @


ID Fans @ Quarterly

Visual Inspections 12 96 1 $4,896.00 none $4,896.00

ID Fans @ 2-Year

Belt Replacements 12 12 2.5 $1,530.00 $1600.00 $3,130.00

SAVINGS $1,766.00


Equipment Type

Number of

Equipments

Number of

Maintenance

Orders Issued

Man-hours/

Orders

Total Cost @


Pre-heater Fans

@ Quarterly

Inspections 8 64 1 $3,264.00 none $3,264.00

Pre-heater Fans

@ 2-Year Belt

Replacements 8 8 2 $816.00 $160.00 $976.00

SAVINGS $2,288.00


Purpose Statement: Why is job being requested

Special tools and Equipment

Drawings


Safety Procedure

Maintenance Procedure


Maintenance Procedure Details Exact Requirements For Completing Task


Maintenance Procedure


Equipment Checkout

Housekeeping


Materials


What is a Maintenance

Task?


Anything pertaining to the necessary basic support and repair

of equipment.

In SAP: A maintenance task is any single maintenance activity.


Task?


Tasks Such As:– Lubrications– Infrared Thermo Graphics– Vibration Analysis– Inspections– Corrective Type Repairs

• Electrical - Replacement of motor• Mechanical – Replacement of gearboxes• Mobil - Replacement of batteries• HVAC – Replacement of filters• Welding - Containers


Task?


Tasks Such As:– Adjustments– Rebuilds– Predictive Monitoring & Analyzing– Wear Based Component Replacements

• Sheaves / Belts• Sprockets / Chains• Shaft Seals• Armor Plates

What is a Maintenance Task?


Maintenance Tasks Importance?

•Write maintenance task to document the knowledge acquired by your senior maintenance technicians, planners and staff before they retire

• Write maintenance tasks to reduce “reinventing the wheel”

• Knowledge Transfer

• Planners and Technicians can issue orders from tasks quickly


• Write maintenance tasks to help bring your new maintenance force up to same level of expertise as existing maintenance personnel and quickly reduce learning curve.

• Write maintenance tasks to eliminate safety issues for employees and equipment.

• Reduces unexpected incidents.

• SAFETY FIRST!!


Maintenance Frequencies

Properly Aligned

Correct Labor &

Craftsmen Identified

Maintenance Tasks With

Well Defined Procedures

Duplication Tasks

Eliminated

Shutdown Requirements

Properly Identified

Production Operations

Established On Maintenance

Plans To Properly Prepared For

Service


Thank You for your attention and interest!

Questions?



[email protected]

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