Lean manufacturing has been around for quite some time and has morphed over the years into variants like LEAN SIGMA, LEAN SIX SIGMA, LEAN AGILE, LEAN Thinking, LEAN Safe, LEAN Control, etc. By definition, LEAN is simply an approach to remove waste from what would be identified as a Value Stream. This presentation will focus on the fact that Reliability is a necessary condition for LEAN and will overview the relationship between the two disciplines, sharing some of the tools that Reliability incorporates to ensure that LEAN is effective doesn’t lose sight of the overall mission effectiveness of the enterprise.. This will be an interactive session through polls to allow the attendees to share their perspectives.
BIO: David is a senior Reliability engineer with experience in multiple industries, including but not limited to medical device development, instrument development, high volume manufacturing, energy, aerospace, commercial vehicles and powertrain development.
Por Carlos Parra, PhD, Profesional Experto y educador de profesionales en Confiabilidad
ABSTRACTO O RESUMEN del tema a presentar
La efectividad de un proceso de integral de gestión del mantenimiento y de la confiabilidad operacional, sólo puede ser evaluada por el análisis exhaustivo de una amplia variedad de factores, que en su conjunto, constituyen la aportación del mantenimiento y de la confiabilidad operacional dentro de un modelo de gestión de activos industriales. Estos procedimientos de evaluación se denominan con el término de “Auditorías”, las cuales, se pueden definir como una “revisión sistemática de una actividad o de una situación para evaluar el cumplimiento de un conjunto de objetivos claves de un proceso de producción”.
Es importante señalar, que no hay fórmulas simples para “medir” los factores claves que afectan las áreas de mantenimiento y de la confiabilidad operacional, tampoco hay reglas fijas o inmutables con validez para siempre y en todos los casos. Los resultados de las técnicas de auditorías aplicadas al diagnóstico de los procesos claves del mantenimiento y de la confiabilidad, deben ayudar a mejorar la rentabilidad del sistema de producción y a disminuir la incertidumbre en la toma de decisiones bajo el enfoque integral de la Gestión de Activos (Normas de referencia: UNE 16646 e ISO 55000).
En síntesis, el siguiente artículo, describe la importancia de los procesos de auditoría y se presenta de forma objetiva, el proceso de interpretación y análisis de los indicadores de Benchamrking en Mantenimiento. Finalmente, se presentan los detalles técnicos (incluyendo casos reales de aplicación) de algunas técnicas de auditoría: MES (Maintenance Effectiveness Survey) y AMORMS (Asset Management, Operational Reliability & Maintenance Survey), utilizadas a nivel mundial para evaluar el desempeño de los indicadores claves del mantenimiento y de la confiabilidad dentro del ciclo de vida útil de un activo industrial.
Abstract: “This session provides insight into the limitations of exclusively using normal distribution statistics for quality program decisions. As useful as the bell curve has been in the past, often it does not model current manufacturing process output adequately at the shop floor level. Justification is provided in the session to adding options for the use of alternate models such as Weibull or lognormal when appropriate.”
Bio for Carl Tarum:
Mr. Carl Tarum is the Director of Software Research at Fulton Findings. He retired from Nexteer Automotive where he worked on Functional Safety for Electric Power Steering. Prior roles included Design for Six Sigma Master Black Belt, where he taught, coached, and managed certification records. As a Reliability Engineer, he developed life testing and reliability predictions for hydraulic systems and new development. He has five patents related to steering systems. Additionally, Mr. Tarum developed the SuperSMITH® YBath™ and Help modules. He has conducted extensive research on p-value estimates for goodness of fits and methods to analyze mixtures of failure modes. He received his B.S.M.E from Montana State University, and his M.B.A from the University of Michigan – Flint.
Bio for Wes Fulton: Wes Fulton is CEO of Fulton Findings. He wrote the first widely-used Weibull plotting program in 1987. That software has been upgraded year by year into the current Windows-based Weibull Engineering package, SuperSMITH(R). It is the only software 100% compatible with Dr. Bob Abernethy’s standard reference, “The New Weibull Handbook(c)”. Mr. Fulton has presented Dr. Bob’s “Weibull Workshop” hundreds of times to technical professionals around the world over the past 30 years. Before that, he worked 16 years as program engineer for AiResearch, managing aerospace projects including the F16 Fighter Leading Edge Flap Drive System (LEFDS) and the Taiwanese IDF Jet LEFDS. His name is on a drive-train shaft patent. He holds B.S.M.E from Georgia Tech and M.S.M.E. from Long Beach State.
Because errors and mistakes are costly, organizations put significant effort into improving operations and increasing reliability. But errors also occur within the problem-solving process. Sometimes organizations make problem solving more complicated than it needs to be. The variety of different tools and methods available can sometimes lead groups to mistakenly focus more on techniques than principles. Regardless of industry, the basics of problem solving apply to all issues, and companies may be forfeiting valuable insights and solution ideas without even realizing it. Avoiding some of these common errors will improve the way people analyze, document, communicate and prevent problems. Attendees will learn: How to minimize blame and the perception of blame in problem solving. Not to let tools distract from the basics. The key parts of a complete problem definition. The important difference between description and analysis. How solutions from one problem can become best practices for an organization.
Bio – Short
Mark Galley founded ThinkReliability, a training and consulting company specializing in root cause analysis and work process reliability. Mark has been leading investigations and teaching workshops on risk and reliability using the Cause MappingÒ method for more than 20 years. He began his career at the Dow Chemical company and obtained his CRE from ASQ in 1993.