SMRP 5 PILLARS OF EXCELLENCE

Pillar 2 — Manufacturing Process Reliability

1
SECTION OBJECTIVES
➤ To be able to recall the
components of Pillar 2 —
Manufacturing Process Reliability
1. Maintain process and industry
standards and specifications
2. Understand the manufacturing
process
3. Manufacturing effectiveness
techniques
4. Safety, Health, & Environmental
(SHE)
5. Manage effects of changes to
processes and plant

2
2.1 MAINTAIN PROCESS & INDUSTRY STANDARDS & SPECS
1. Review and understand specifications and standards
2. Identify and analyze gaps between industry standards
and company practices
3. Develop and implement plan to close gaps
4. Measure results and adjust plan

What other standards apply within your organization?

3
2.2 UNDERSTAND THE MANUFACTURING PROCESS
1. Identify what you make and
how you make it
2. Identify process variability and
relationships affected by M&R
3. Identify customer
requirements
4. Relate costs of best practice
M&R practices to customer
value
5. Develop a plan to capture
benefits identified

4
2.2.1 IDENTIFY WHAT YOU MAKE AND HOW YOU MAKE IT
➤ Process training
➤ Interactions with process managers and operators
➤ Participate in operations process improvement teams
➤ Spend time with maintenance craftsmen

5
2.2.2 IDENTIFY PROCESS VARIABILITY
➤ Statistical Process Control Variances
➤ Meetings with operations organization
➤ Serve on problem solving teams

People

Materials Production Process

Utilities

6
2.2.3 IDENTIFY CUSTOMER REQUIREMENTS
➤ Visit customers to identify reliability requirements
➤ Discuss customer reliability requirements with sales
organization

Voice
of
the
customer
7
2.2.4 RELATE COSTS OF BEST M&R PRACTICES TO CUSTOMER VALUE

➤ Cost of unreliability (COUR)

➤ Benchmarking

metroforensics.blogspot.com

8
2.2.5 DEVELOP A PLAN TO CAPTURE THE BENEFITS

Vision
Implementation
Values
Plan

Communication
Mission
Plan
Plan
Resources Goals

Tasks Objectives

9
2.2 EXERCISE
➤ Five Minutes
➤ Make a list of the current measures your organization uses to
relate equipment reliability to managing its value stream

10
2.3 MANUFACTURING EFFECTIVENESS TECHNIQUES
1. Develop measures to relate equipment reliability to
manufacturing process
2. Establish relationship between maintenance and
operations for most effective asset management

If we don’t measure it we cannot improve it!

www.tpslean.com

11
2.3.1 DEVELOP MEASURES

OEE = % Availability X % Rated Output X % First Pass Quality

12
2.3.2 ESTABLISH RELATIONSHIP BETWEEN M&R AND OPERATIONS
➤ Total Productive Maintenance (TPM)
➤ Create Manufacturing Teams
➤ Cross-functional problem solving and process improvement
teams

www.tpslean.com
13
2.3 EXERCISE
➤ Fifteen minutes
➤ Discuss your organizations use of the Overall Equipment
Effectiveness (OEE) KPI.
➤ How were the throughput and quality standards set?
➤ How does your system handle rework?
➤ Discuss what your organization does to create teamwork
among operations, engineering, and maintenance

14
2.4 SAFETY, HEALTH, & ENVIRONMENTAL (HSE)

1. Identify benefits of
good safety practices to
the bottom line
2. Identify specific HSE
issues applicable to the
manufacturing process
3. Identify applicable
regulatory issues and
activities
4. Prevent acceptance of
normalized deviation Every Employee
Home Healthy & Safe
Every Day
What About Security
15
2.4.1 IDENTIFY BENEFITS OF GOOD HSE PRACTICES
➤ Costs
➤ Employee Morale
➤ Public Perception

16
2.4.2 IDENTIFY SPECIFIC HSE ISSUES
➤ Process Hazard Analysis
➤ Job Safety Analysis
➤ Accident investigation (RCA, etc.)
➤ Safety Audits
➤ Bow Tie Analysis

17
2.4.3 IDENTIFY APPLICABLE REGULATORY ISSUES & ACTIVITIES
➤ HSE required inspections, tests, and PM activities
➤ Safety equipment inspections (extinguishers, PPE,
eyewash/shower, etc.)
➤ Safety inspections of process and maintenance equipment
➤ HSE activities associated with maintenance activities
➤ HSE specifications that regulate how maintenance, reliability,
and design activities must be done
➤ Boiler maintenance regulations
➤ Water treatment process and equipment
➤ Permit regulated operations

18
2.4.4 PREVENT ACCEPTANCE OF NORMALIZED DEVIATION
➤ Internal audits
➤ Third party audits

19
2.4 EXERCISE
➤ Five Minutes
➤ Discuss the different ways your organization ensures that its
HSE goals are met
➤ Does your system encourage the right behaviors?

20
2.5 MANAGE EFFECTS OF CHANGES TO PROCESS & EQUIPMENT

1. Create a process to
identify when changes
are being made (MOC?)
2. Apply analytical
assessment process to
identify effects of
changes being made
3. Implement and manage
changes

21
2.5.1 CREATE A PROCESS TO IDENTIFY WHEN CHANGES ARE BEING MADE

➤ Benefits
➤ Minimizes adverse impacts
➤ System Integrity, Security, Stability, Reliability
➤ Maximizes productivity
➤ Provides stable production environment
➤ Ensures proper level of technical completeness
➤ Provides appropriate level of management approval and
involvement

22
2.5.2 APPLY ANALYTICAL ASSESSMENT PROCESS TO IDENTIFY EFFECTS OF CHANGES

➤ Reliability-Centered Maintenance
➤ Failure Modes and Effects Analysis
➤ ????????

23
2.5.3 IMPLEMENT AND MANAGE CHANGES
➤ Policies
➤ Procedures
➤ Designs
➤ Process/Equipment Modifications

24
2.5 EXERCISE
➤ Five minutes
➤ Make a list of the triggers your organization uses to initiate
the MOC process.

25
QUESTIONS
➤ What questions do you have about the material we have
covered in Pillar 2?

26