Chapter 4: Vital People – Kalveer (Machine Warriors)
The individuals are primarily responsible for ensuring production from all types of equipment is at or higher than rated capacity without interruption. In addition, the role involves understanding breakdowns, educating operators on machines-care, doing timely cleaning & refurbishing to avoid untimely interruptions, managing the life of parts, stock of critical spares, etc.
To deliver on these roles, they established
- Machine Hierarchy – The first and most important task is that every asset (machine, equipment, arms, etc.) in the company has a specific address, including
- Plant / Unit
- Process Line
- Machine Name & Number
- Main & sub-assembly Name
- Part with a unique number
- Common parts with the flexibility to assign to a hierarchy.
- Machine History Cards – Record every event on the machine. It can be a breakdown, planned maintenance, product changeovers, tools changes, repair, etc. For each event, including information like
- Address the event using machine hierarchy to enable data segregation for analysis.
- Which spare part was changed,
- The crew involved in repair (names, skills),
- Time of the event (start / end),
- Reason of event/failure with corrective actions and
- Add any other helpful information to assess the machine’s health and enables improvement.
- Machine Event Reporting & Closure – The machine operator reports each event, and someone (operator himself or maintenance technician) attends it. An expert inspects, and the operator himself closes the event. In addition, a neutral agency like royal auditors frequently audits the system and correlates event data with actual performance.
- Know My Machine Initiative – Every process owner knows about the machine they operate. There are four levels of knowledge. L1 is for the trainee, L2 is for the Assistant operator, L3 is for independent operators, and L4 is for Senior Operators. Operators received the following knowledge at different levels.
- L1 – How to operate
- L2 – How each sub-assembly works & routine maintenance checks (Clean, Lubricate, Inspect & Tighten)
- L3 – How to set up and changeover within the standard time
- L4 – How to repair / essential maintenance and do PM checks
- Planned Maintenance System – The Kalveer sets periodic machine health check-up systems. Based on checks, do necessary corrections, repairs, and replacements to avoid unplanned stoppages. The system includes
- Identify Checks – First, we clean the machine thoroughly to identify all deteriorations and try to eliminate their causes. If the team cannot identify causes, we set the periodicity of checking the damage for timely repairs.
- Develop Checklists – We distribute checks into two categories, viz. (1) Need no stoppage (Routine checklist) and (2) Need Stoppage (PM checklist), and then suitably identify the frequency of checks, standards for checks, and actions to be taken in case of deviations.
- Establish Schedules & Duration – The date and exact time of each check are declared, agreed upon, and managed. Veers identify deviations in terms of date, time duration, and checkpoints and discuss to avoid recurrence.
- Establish Reliability Measures – Kalveer analyzes each piece of equipment up to part level for reliability and captures any trends for improvements. Some of the possible measures are:
- MTTR – Mean Time to Repair
- MTBF – Mean Time Between Failures
- Part Reliability Ratio – Measured as the ratio of “time between schedule maintenance and first failure” and “Duration Between two scheduled maintenances.”
- Scheduled to Unscheduled maintenance Ratio – Measures as the ratio of “duration of maintenance activities due to scheduled stoppages” and “duration of repair activities due to unscheduled stoppages.”
- Schedule Maintenance Discipline measures, e.g., schedule adherence, time slippage ratio, activity slippage ratio, etc.
This Veer’s actions keep each asset in the most reliable condition, ensuring availability during peace or war.
Key Principles – Basic Machine Maintenance, Machine Hierarchy is the basic skeleton, machine history enables performance, machine event controls are building blocks of reliability, education on the machine is the foundation of success, Planned maintenance is the only way and measure performance to understand progress.
Relevance – Usable assets need continued maintenance