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Manufacturing Improvement / Reliable Maintenance

Reliable Maintenance Strategy

A 5 Step Process 
Does your maintenance team feel undervalued and over worked?  Are you unsatisfied by the apparent lack of direction within the maintenance team? Does your maintenance department raise your anxiety levels on a regular basis?

A strategic maintenance plan will remove these emotional chains. Our TPM trained team will guide you through a 5 step process starting with an audit over 28 key maintenance areas, so you’ll have a clear understanding of the maintenance team’s position against gold standard. The final step is a 9,000+ word strategy document plan giving the maintenance team a clear goal and a detailed plan of how to get there.

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Asset Care

If you’re experiencing any of the following, our Asset Care programme will help:

  • Frustrated by highly skilled technicians performing low level tasks?
  • Is your maintenance team crippled by the high level of PM’s they have to complete?
  • Are you alarmed by the high proportion of breakdowns your plant is experiencing?
  • Worried that your operators are not taking ownership for their machines?

A combined Asset Care / Autonomous Maintenance approach involving operators and engineers working together on key equipment and using a TPM approach is the best way to increase reliability. Through working with engineers and our TPM Specialists on an Asset Care project, operators increase their mechanical ability and start to take ownership for their machines. They will be able to perform simple maintenance tasks such as changing wear parts and basic lubrication, freeing up the engineering team to perform pro-active rather than reactive duties.

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PCS-SOS

Powerful Problem Solving
Recurring breakdowns can be a major cause of anxiety for any manager. The feeling of disappointment can be huge when a machine breaks down for the same reason over and over again. The pain of missed orders and the cost of idle labour during lengthy breakdowns can be crippling.

A key part of an effective maintenance strategy is learning lessons from what currently goes wrong. Just as aviation safety and reliability has been massively improved over the past century in part through statutory air-crash investigations, so Significant Outage investigations should form part of the approach to improving factory reliability.

Based on the exceptionally powerful problem solving approach PCS, the Significant Outage investigation System we recommend is called PCS-SOS which:

  • Targets the unplanned events that hurt
  • Identifies weaknesses within maintenance systems and approach, and implements 100-Year solutions so they do not happen again
  • Provides a breakdown history that can be used to analyse the performance, trends, and underlying issues of the maintenance approach

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Early Equipment Management (EEM)

Building High Efficiency at the Design and Installation Stage
Making changes post installation typically costs 10 times more than engineering them in at the design phase. Frustratingly, the cost of the engineering intervention to rectify poor performance post project will cost a small fortune. A project that is poorly planned can result in 20 years of poor performance, angry operators and a disillusioned maintenance team. Can you afford 20 years of exasperation?

Establishing an effective EEM process could save you huge sums, and ensure that your commissioning goes well, and future good performance is built into the plant. Although EEM normally comes toward the end of the TPM journey, if you are considering installing capital equipment our TPM trained Specialists could help you with the design and installation process.

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Testimonials

Our cooperation with Lauras International has yielded significant improvement across the plants in East Asia and I have recommended the cooperation be implemented across our other regions and suppliers

Jose M. Chao Diaz Senior VP Supply – Developing Markets

The focussed homework, linking the learning to ongoing behaviour and leadership habits, was particularly useful. Excellent 5* training.

Front Line Manager on Aspire Programme