Original Date: 04/24/2006
Revision Date: / /
Information : Facility Maintenance
The preventive maintenance program for Midwest Metal Products’ equipment has resulted in less downtime, increased quality from better-maintained equipment, and a safer work environment for employees. Formally scheduling maintenance periods in the material resource planning system and providing standardized procedures has ensured the completion of required maintenance, with employees more knowledgeable of their equipment.
Midwest Metal Products (MMP) was faced with the need for more reliable equipment in its metal fabrication facility. Metal fabrication and paint and powder coat shop-equipment downtime was periodically delaying production schedules and increasing costs. Downtime was often attributed to the lack of maintenance necessary to keep equipment performing at a high level of reliability.
MMP implemented a comprehensive preventive maintenance program to correct these deficiencies and limit critical equipment downtime. Reduced costs for corrective maintenance, improved quality, and enhanced safety were additional goals of the new program. All areas of the plant from metal fabrication to welding and paint booths were incorporated into the plan and adapted to individual equipment needs. The following components were included: A detailed description of required maintenance was developed and put into a week-by-week schedule
Partnerships with companies that provide cooling-system equipment maintenance and duct- cleaning services were determined necessary and put in place
Maintenance actions were divided among maintenance support staff, equipment operators, and outside contractors for some specialized equipment
Job travelers for each department were developed and provided scheduled maintenance task procedures to ensure proper completion.
A key aspect of the program was to enter periodic maintenance periods into the plant’s material resource planning (MRP) and scheduling system. Operators are provided assistance as necessary to complete maintenance during these periods. Formally scheduling the required maintenance ensures that preventive maintenance does not compete with scheduled operations.
This new preventive maintenance program has increased employee involvement and buy-in to the need for proper care and maintenance of MMP equipment. The operators conducting maintenance on their equipment during scheduled downtimes have also gained increased knowledge of their equipment.
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