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Current Quarter: Q2-2018
Record-able OHSA Events this Quarter
For the week of: May 14, 2018
Client Identified Events this Quarter
We were working with a client who was struggling with a problem that’s far too common in todays manufacturing sector.
Another one of their key maintenance guys was retiring and they were extremely concerned about how they were going to replace him.
Production was at record levels, they were introducing new product lines, but their ability to maintain their equipment and keep their OEE within acceptable limits was becoming a real challenge.
Using KPI data to manage any process is essential if the goal is to improve OEE while optimizing cost. The problem happens when you are using incorrect data to make decisions. In this video we tell the story of an Automotive Parts manufacturer that was using RI to manage the concentration in their sumps. Operators had strict SOP's, with their corrective actions clearly defined. The problem is, what they were measuring as concentration was really contamination, so no fluid additions were being made. Fluid Performance degraded, OEE dropped and the facility was struggling to meet their production and quality targets.
When there's a customer detected quality event, all hell can break loose. There's missed customer commitments, potential penalties, a loss of reputation and trust that can hurt your relationship with your client, etc. This story is about a facility that had such an event, and was looking to make a change to ensure the problem never happened again. Unfortunately they fell into an all too common trap. In the absence of data, they made some assumptions. They formed an opinion about what the problem actually was. And that opinion had them spending money, time and resources while increasing their cost per part that didn't necessarily address the root cause.
Manufacturing at World Class levels is a relentless pursuit of 100% quality, 100% on time, at the lowest cost possible. Its about increasing efficiency, while eliminating waste and wasteful activity.
Plants and plant managers are always on the lookout for how to reduce costs while at the same time improving OEE and keeping their resources focused on high value activities.Unfortunately sometimes, cost reduction efforts can miss the big picture, especially when these initiatives are solely focused on reducing unit costs.