dematic best maintenance practices track/session 2... · best maintenance practices for the real...

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DEMATIC - CONFIDENTIAL

Best Maintenance Practices for the Real World



What is the philosophy of the organizational stakeholders? Reactive: Run to Fail Proactive/Predictive: Prevent issues before they occur

Ownership Strategy

2



Why is Maintenance so important?

3

Cost of downtime

Productivity

Missed shipments

Expedited shipping

Equipment life



Auditing as part of a responsible maintenance program

4

- Maintain Increased reliability Manpower efficiency On-time shipments

- Monitor Remote diagnostics Alert monitoring

- Continuous improvement Safety Training Parts management

- Modernize

Longevity

Performance

Functionality

- Audit

Wear/damage

Maintenance practices

Looming obsolescence

Preparedness (parts, etc.)

Practices (safety, etc.)

Design (still match need?)



Discovering impending problems More flexibility in

planning repairs the earlier issues are detected Getting operational buy

in on fixing it now or rolling the dice An outside set of eyes

will catch things that are problems but considered situation normal for the crew

Why audits should be part of every maintenance program

5



Developing your audit schedule

6

Start somewhere and adjust as time goes on Tune the audit frequencies based on category and experience. Monitor things like…

– Have I seen changes in system availability? – Have I gotten surprised by obsolescence? – Have I gotten caught with insufficient budget?

TYPICAL AUDIT SCHEDULE

AUDIT CATEGORY Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4DesignOwnershipModernization

YEAR 1 YEAR 2 YEAR 3 YEAR 3



Strategies for auditing

7

Who should conduct the audits? – Internal vs. external – Frequency Who should you talk with while auditing?

– Operators – Maintenance – Senior management



Non-intrusive methods and tools

Daily Audits

8



Equipment

9

What type of items should you look for during an equipment audit?



Tablet with stylus

Auditing tools

10



Documenting audit results

11

Computerized Maintenance Management System (CMMS) Benchmark system availability

over time Document audit findings Develop correlations Define the cost of ownership Establish trends over time



Training

12

Weekly training sessions

Peer to peer training

Not top down training

Each person researches topic

Make presentation to the team

Access manuals etc. for research

Obtain comprehensive view

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwiUlrzbzJvNAhUOTFIKHejpAMsQjRwIBw&url=http://www.getnews.co.za/story?id%3D531&bvm=bv.124088155,d.aXo&psig=AFQjCNHBeArEBjJ42gS3sBipe_8ip1y2zA&ust=1465584185081116



Utilize data to increase efficiencies

– Call center activity – Remote alert monitoring

activity – CMMS reports

Advanced tools and data analysis

13



System Performance Indicators

– System Uptime by Equipment

– Mean Time Between Failures

– Mean Time to Repair – Total Count of Errors – Top 4 Errors – Fault Listing – Parts Management – Photos

Measuring performance and progress through KPI reports

14



System Uptime

15

Target 98% Track sub systems so

things don’t get lost in the averages Graph results



Mean Time Between Failure

16



Mean Time to Repair

17



Total Count Errors

18



Top 4 Errors

19



Parts Management

20



Are you getting the most from your CMMS? – Reporting – Ability to connect with a mobile device – Inventory management Barcode parts and use a scanner to

identify Automated re-order

– Web based solution – Generate work orders by technicians

skillset

CMMS

21



Dematic Sprocket Features

22



Specialty Tools

23



AGV Idler Wheel Fixture

24



Cost < $500

Drive Plate Removal Tool

25



Cost < $500

Drive Assembly Stands

26



Cost < $500

Tow Dolly

27



Downtime Saving Practices

28



Solutions for Unstable Power

29

Many devices like PickDirector Net Controllers, Scales, PLCs are sensitive to voltage fluxuations and power surges Adding battery backups will protect these devices and therefore improve the

uptime of the system



Three Phase Voltage Monitor

30



RS200 Transition Bed Belt Tracking Stand

31



Thank you

dematic best maintenance practices track/session 2... · best maintenance practices for the real...

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