hot topic event portsmouth – 26/3/08

Hot Topic event Portsmouth – 26/3/08

Auditing, Benchmarking & Awards in maintenance departments

Cosmas Vamvalis Implementations ManagerATLANTIS Engineering

Maintenance Auditing, Benchmarking & Awards March 2008, Portsmouth

CMMS


SUCCESS FACTORS

• Management support (***)• Acceptance of employees (**)• Correct selection of CMMS • Implementation of accompanying changes(*)• Involvement (*)• Stability of employees (*)• Adequate training during implementation (*)• Adequate follow up and monitoring (**)


MABA: THE NEED

• No CMMS is fully utilisedCURRENT SITUATION

• Lack of continuous improvement process

REASONS• Daily routine & job pressure of technicians• Lack of top management involvement (targets,

indicators)• Lack of maintenance setup picture on other factories• Lack of motivation


MABA: THE INSTITUTION

Participation of all companies that apply the computerized maintenance system AIMMS of ATLANTIS Engineering (about 50) from Greece & Cyprus



Participation of all companies that apply the computerized maintenance system AIMMS of ATLANTIS Engineering at Greece & Cyprus

Annual auditing taking into account 98 criteria, of the exploitation degree of the CMMS and maintenance department organisation level


AUDITING PROCESS

Three ways for auditing

Directly from the database (D)

Discussion with the user (U)

Report sent by the user to the auditor (R)


AUDITING PROCESS

A. MAINTENANCE ACTIONS C1 C2 C3 C4

Machines D 474 166 496 99

Number of breakdowns(per machine)

D2217(4,6)

113(0,68)

1070(2,1)

452(4,5)

Average words/breakdown D 8,5 6,8 6,0 2,6

Do you analyse breakdowns data (worst machines, machines history) U

Have you reached to specific conclusions by analysing breakdowns data ? Have you taken specific actions as a result ?

U

Did you make a report to the factory management concerning actions taken ? R


AUDITING PROCESS

Do you give printed work orders concerning PM,Corrective Actions, Breakdowns ? (or Orally)

U

Prototype time per action D - - - -

Scheduling of actions D - - - -

How fast corrective actions (not breakdowns) are completed (in Days) ? (Number of Corrective Actions) D -

0,21(80)

2,46(843)

1,52(1808)

Do you know how your engineers have spent their time? (hours per technician & day) D 7,8 5,0 5,5 1,6


AUDITING PROCESS

B. PREVENTIVE MAINTENANCE C1 C2 C3 C4

Number of existing PM schedules (per machine)

D527

(1,21)89

(0,53)39

(0,07)60

(0,60)

Do you have drawings on your PM schedules? D 0% 0% 0% 0%

No of schedules having at least one execution (daily schedules) D

245(46%)

64(71%)

35(89%)

58(97%)

Do you record corrective actions as a result of PM schedules ? D

8(1,52%)

0 0 0

Do you monitor machines availability ? D 98,60% - - 95,47%


AUDITING PROCESS

Is there a target for next year Availability ? U

Time spent for PM compared to breakdowns (projects) D 0,45 0,93 0,30 2,42


AUDITING PROCESS

C. SPARE PARTS C1 C2 C3 C4

Do you Record spare parts requests ? D 0 0 35 0

Do you record suppliers offers? D 15 7 5 0

Do you send electronically your offer requests to your suppliers? U

Do you keep track of expected provisions? U

Do you make valuation of your suppliers (price, delivery time, quality, etc.) D 0 0 0 0

Do you record the Row & Bin no on your spares? D229

(52%)451 0 0


AUDITING PROCESS

Are there labels on the Bins ? U

Do you use the minimum stock level for your spares? D 0 415

101(17,41%)

27(0,66)

Do you record machines spare parts?(per machine)

D430

(0,91)1078(6,49)

306(0,62)

631(6,37)


AUDITING PROCESS

D. STATISTICS – MISCELLANEOUS C1 C2 C3 C4

Do you take into consideration the maintenance labour cost? (hourly cost of engines) D - 95% 92% -

Do you take into consideration spare parts cost?(value on spares)

D 13% 3% 41% 77%

Loss of production cost? (cost of being idle) D - - - -

External suppliers cost? D - 24% 57% -

Do you use the replace/repair decision? U

Do you use CMMS reports for your company’s ISO D 62,5% 45% - -


AUDITING PROCESS

Do you keep track of vehicles actions (insurance, tax,..) D - - - -

Do you have automatic link of your CMMS with your ERP? U



Participation of all companies that apply the computerized maintenance system AIMMS of ATLANTIS Engineering at Greece & Cyprus


Delivery of printed study in each company with:• Analytic grades• Benchmarking • Proposals for priorities – improvements

-> Meeting with factory management



Participation of all companies that apply the computerized maintenance system AIMMS of ATLANTIS Engineering


Prize award to the three top score applications in the annual«MAINTENANCE FORUM»

Delivery of printed study in each company with: Analytic grades Benchmarking Proposals for priorities – improvements

-> Meeting with factory management


MABA: THE BENEFITS Adoption of policies of continuous improvement and increase

of exploitation level on the CMMS

More active participation of top management, through the possibility to keep track specific targets/indexes

Competition is developed among factories

There’s a motivation for all technical departments, to become better every year!


MABA: THE FUTURE

• Increase of reliability

• Increase of scientific character

• Increase of flexibility

• Increase of participant companies/countries

hot topic event portsmouth – 26/3/08

Documents

benchmarking awardsmarch

rmaintenance auditing

auditor r maintenance

greece cyprusannual

result of pm schedules

specific actions

fast corrective actions

portsmouthauditing processdo