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Lean MaintenanceReducing waste

and cost

02

Lean maintenance programmes focus on driving efficiencies within the asset management and maintenance areas of manufacturing operations. As with all lean activities it is a journey and not a destination - the continuous improvement of an evolving process. Toyota, who have been applying lean for over 95 years continue to focus on lean maintenance as a priority as they recognise its impact on the smooth flow of operational lines. Lean maintenance is often referred to as Total Preventative or Total Predictive maintenance.

Many organisations that have been implementing Lean for decades are only now giving maintenance the attention it deserves. Those new to the adoption of lean should mark it as a top priority. Efficient maintenance programmes can drive significant improvements to productivity and process improvements, resource efficiencies and importantly significant financial benefits.

Advanced Technology Services provide maintenance solutions to the world’s largest manufacturers such as Caterpillar, Eaton, Honeywell, Dell and Ford. They have identified ten critical steps for implementing

a successful lean maintenance programme

Step 1

Apply organisation to the work areas

Utilising Five S principles within the

maintenance area will provide a sound

basis for identifying value and waste

within the maintenance process.

Step 2

Identify Value Streams and Strategy Maps

Understanding the value streams will help

you identify which activities add value and

which do not and can therefore be removed.

Strategy maps map the lean activities with

the companies overall strategic goals.

Step 3

Optimise Planning

Implementing and utilising maintenance

good planning and project management

will drive significant efficiencies and

improvements within maintenance activities

Step 4

Prioritise, repair and refurbish

In applying lean maintenance you are

looking to reduce waste, cost and improve

productivity. To achieve this it is important to

get both plant and maintenance equipment

to a good standard and then maintain it.

In the news Lean maintenance Reducing waste and costs

03

Step 5

Implement predictive strategies

Predictive maintenance provides a forecast

schedule of planned maintenance activity

based on historic data. Predictive strategies

deliver considerable cost savings and

improve asset longevity and they are

shown to significantly improve safety.

Step 6

Track metrics

Critical to the success of any lean

programme is the need to track key metrics.

They will provide information to identify the

most appropriate projects and can justify

expenditure when required. ATS use the

following in each of their factories to steer lean

maintenance: Key performance indicators

(KPI’s); Overall equipment effectiveness (OEE)

and Mean Time Between Failures. (MBTF).

Step 7

Perform Root Cause Analysis (RCA)

RCA is a method of problem solving that

establishes the fault or cause of a problem.

It is frequently used within the manufacturing

operations and should also be applied in

maintenance to establish machine failure

or break-downs.

Step 8 Employ the tools of Six Sigma

Most organisations will use a computerised

maintenance management software (CMMS)

which can be used for preliminary six sigma

evaluation. Once useful data is gathered

within the CMMS tracking failure causation,

Six Sigma initiatives can be instigated.

Step 9 Evaluate Performance

As with any project or activity it is essential

to report on key financial and strategic

measures to justify the continuing

investment in the process.

Step 10 Continually improve

As mentioned previously, lean is not a

destination but a journey of continuous

improvement, new or changing assets will

mean a need to continuously update the

programme of lean activities.

Focusing on an effective lean maintenance

strategy will pay off both financially and in

terms of productivity. It will improve work

place satisfaction and improve safety. This is

the core of manufacturing competitiveness.

In the news Lean maintenance Reducing waste and costs

Kulwinder Bhamber, Supply Chain/

Technician at Brierley Hill, was called out

to look at a breakdown on a machine

when he noticed an issue with the

locking mechanism for the tooling.

The spring loaded mechanism is

supposed to lock the tooling into position

for when material is required to be

punched. Without this locking mechanism

in place, the tooling can move freely and

the materials will vibrate, putting both the

machine and operator at risk.

Kulwinder locked off the machine and

assessed the job to get to the spring loaded

mechanism, which required the

Chris Smith - Site Supervisor, awards Andy Kulwinder Bhamber, Supply Chain/Technician

main head, to be stripped down.

He found that the spring inside had

snapped, so a suitable replacement was

fitted and the mechanism was tested and

confirmed as serviceable. This was an

excellent identification of an issue that

could affect customer safety, and a

well-managed solution was engineered.

Live safetyOur first priority

04

Kulwinder Bhamber - Locking mechanism

HAZARD OF THE MONTH

WINNER

During a reactive maintenance work

order, Julian Burrows (ATS Technician at

Havant) was required to look into a test

rig electrical cabinet to check for tripped

overloads, and visually observe input and

output indicators. Upon inspection, a strong

burning smell was immediately obvious

and an overheated wire was identified.

Julian immediately powered down and

locked out. The fuse holder was too hot to

touch so was left to cool, before the fuse

holder and damaged wiring was replaced.

This situation would have only gotten worse

and could possibly have caused a short

circuit and fire hazard had it not been

found. Great work Julian.

05

Proportional Test Rig asset #6511

Before

After

06

ATS Wolverhampton Diamond award for safety

Andy Plant - ATS Supply Chain Specialist and Julian Budd CAT Facilities Manager

“This is a great achievement for both ATS and Caterpillar, showing how we are both working in unison to improve our safety standards, this is just another great example of the importance of the great safety culture within the ATS business.”

07

Delight customers

Congratulations to ATS at Wolverhampton on

achieving a Diamond award for Safety.

All contractors on site, including ATS, have gone

731 days with no recordable incidents. Since ATS’

inauguration on 1st August 2010, there have been

no recordable accidents. This is 1122 days of safe

working within the department. The company’s

primary cultural commitment is ‘Live Safety’,

which is implemented in several ways, including:

• Daily safety talks

• Dedicated on sight H&S representative

• Safe working practices including things such

as LOTO and PTA

• Qualified and conscientious work force

• Adherence to H&S laws and PPE requirements

• Safety observations and safety training

08

Developing people

TM

In January 2013, it was announced the

strategic decision by ATS to implement a

new global business system to improve

our ability to effectively manage

our most important resource – our

people. Throughout 2012, multiple

vendors were reviewed to ensure that

the best system was selected, not just

for today but for our future.

Workday was selected as the system for

ATS and it went live globally from the 9th

September 2013.

“Workday” is an Enterprise Business

Management System, consistently rated

one of the best and most innovative

in the industry. Through Workday,

our employees will have the ability to

proactively manage their careers and

professional development.

In addition to this the deployment of

Workday will provide:

• Self-service capabilities for

managers and employees,

eliminating over a dozen

disconnected systems

• Greater insight for managers

to drive business results

• More robust, timely reporting

capabilities with information in

the hands of decision makers

• Cloud-based storage with

24 x 7 availability

09

Initial training for employees on the

new system took place between the 26th

August 2013 and the 6th September 2013

and we want to thank everyone for their

participation. During September and

the beginning of October, training will be

supported with individual coaching sessions

where required and weekly tasks will be

issued with instruction sheets on how to

complete processes within Workday. First

week training focused on logging onto the

system and updating holidays for 2013.

The Change Champions at each site

available to support employees with

Workday are as follows:

• Brierley Hill – Amy Nutting

• Wolverhampton – Emily Mathews

• Havant – Ross Tolliday

• Titchfield – Karen Mattingly and Mike Ford

We would like to thank the Change

Champions for their contributions and

support of this project.

Pictured leftGemma Turner ATS Human Resources Manager

10

Recruitment ATS has set a goal to be a 110 million dollar

business by 2023, and to achieve this we

need to attract over 1,000 employees. To

enable us to attract and recruit the best

possible talent to complement our existing

teams we decided to appoint our first

Recruitment Manager, Anna Prince in August

2013. Historically ATS has relied on external

recruitment agencies and bringing Anna on

board is a first step towards a more integrated

approach to resourcing our business.

Anna has extensive recruitment experience

and she will concentrate on implementing

and delivering a UK specific recruitment

strategy. Raising the profile of the ATS brand

within jobseekers will be an important

feature of her role.

Anna Prince - Recruitment Manager

By approaching recruitment proactively

through understanding our business

and using modern recruitment tools,

techniques and social media Anna will

work on creating talent pools across the

UK. This will add value to our customers

eliminating their recruitment challenges

in terms of time, cost and the risks

involved, as ATS will be in contract with

the right people with the right skills to

support existing sites and to prepare in

other areas as ATS expands.

Enhanceprocesses

.

A note from Anna “For me ATS ticks all the boxes.

I’m delighted to have joined ATS at this

exciting stage and I’m looking forward

to be part of its growth. Getting

Recruitment right, especially when

adding to existing teams, is crucial.

I am interested in your views and any

ideas you have for filling our vacancies

and streamlining our processes and

would be happy to hear from you.”

You can contact Anna on the

following details:

Email: aprince@advancedtech.com Phone: 01536 311654

11

£1000 BONUS Recommend a friend and get £500 when they start employment with ATS and £500 after their first six months Terms: Payment is on completion of

the probationary period.

12

Drivinginn vation

eFactory Connect

ATS eFactory Connect provides a 24/7 call centre for ATS

Technicians, allowing them to dial-up to live maintenance specialists

that can provide assistance on a wide variety of technical and

maintenance related tasks.

The purpose of the programme is to provide site technicians an

additional technical resource to assist in developing solutions.

The programme has already demonstrated enormous benefits in

reducing downtime, minimising maintenance costs, and as a

result a benefit to our customers.

e100,000

manufacturingassets

13

eFACTORYCONNECT

Watch here

400MajorBrands

eFactory Connect can help with…

• Troubleshooting

• Researching machine specific procedures

• Finding Machine Documentation

We are encouraging technicians to call eFactory Connect anytime

a site needs help with any maintenance related issues that they are

unable to resolve immediately; during the troubleshooting/repair

process; and always before calling the OEM.

The provision of this service will reduce costs for our customer as we will

reduce the reliance on the OEM’s. We will improve the speed of fault

resolution through immediate and responsive advice. It will also help the

site improve its performance metrics through more efficient tracking.

14

During June Eaton asked ATS to support

them on 2 safety projects which had been

instructed by the Global Eaton H&S team.

The first was a LOTO identification project

where we needed to document and

highlight the LOTO procedure on all of the

machines. The second was to install tamper

proof screws to all covers and guards. The

onsite team did not have the resource to

complete these projects in a reasonable

time, so we recruited a Project Engineer to

support these projects.

Richard Aylen joined and from day one has

demonstrated leadership in driving safety

and delivering these projects. Both projects

were completed on time and in budget to

the great delight of the customer.

Due to the success of these 2 projects, we

have now been asked to undertake further

projects on behalf of the customer.

Richard Aylen - Project EngineerAwarded by Rick Lyford -

Eaton H&S Manager

Richard was awarded a best practise

recognition award by Rick Lyford (the

Eaton H&S Manager) for his consistent

high levels of safety. Richard clearly

demonstrates what it means to Live Safety.

Richard Aylen Best Practice award

Demonstrate leadership

15

A 3 day Predictive Analysis Initiative

was held at Eaton Havant to support

the Health Assessment which had

been carried out on 8 key machines.

The event was used to analyse the 8

machines using both thermal imaging

and Ultrasound equipment in order

to improve machine efficiency and

eliminate energy lost through air leaks.

11 significant air leaks were located and

repaired during the event, with a total

air loss reduction of more than 63 CFM.

6 issues were detected and investigated

through Thermal analysis, 1 of which was

raised as an urgent W/O.

The event not only demonstrated

the power of predictive maintenance,

but also achieved customer savings

of £24,363.86.

Predictive Analysis Initiative

16

1YR Service award

Congratulations Binh La – Desk Side Technical Engineer

at Church Crookham for achieving his 1 year service award.

SERVICE

awards

3YRS Service award

Congratulations Paul Setterfield – Senior Technician

at Havant, for achieving his 3 year service award.

17

Stefan Korn Eaton HavantCongratulations to Stefan Korn, Technician

at Havant, for winning cost saving of the

month. Stefan was contacted by a US

colleague asking for help with translating

a German machine document. The

document was 70 pages long and required

translation into English as quickly as possible.

An internet search revealed quotations

ranging from £30 to £70 per page

depending on the speed and quality of

the document. Stefan downloaded the 70

page document on to his own computer,

printed it off and translated the entire

document before returning the scanned

document the following day. All the work

Stefan carried out was done during his own

time using his own computer. Not only has

Stefan delivered an excellent cost saving to

the company, but he delivered results and

demonstrated leadership.

COST SAVING OF THE MONTH awards

Stefan Korn - Technician at Havant is awarded by Andrew Purchase

18

ATS Global

Due to an 85% three year growth rate,

Advanced Technology Services continues

to move up the leaderboard of America’s

fastest growing companies.

The list represents the most comprehensive

look at the most important segment of

the economy - America’s independent

entrepreneurs.

ATS joined the ranks of the top 5000 best

performing businesses in 2011 and has

continued its success, rising this year in the

listings. Since 2011, the company has also

added over 1,144 jobs, bringing its current

staff totals to 2,999 employees.

According to Jeff Owens, President of ATS,

“Our considerable growth is due to

two drivers in our business; the need for

manufacturers to increase the performance

and efficiency of production assets, and

the new technology that ATS has brought to

manufacturing.

The US success comes soon after the UK

division achieved a similar accolade in the

UK’s Best Companies Ones to Watch List that

also recognises high growth and dynamic

organisations. Derek Hill of ATS UK commented

that “It is our commitment to building and

delivering value for our clients which continues

to drive our success around the world.

Advanced Technology Services Achieves Fastest Growing Company Accolade from Forbes!

19

CONTINUOUSIMPROVEMENT

Live SafetyDelight CustomersDevelop PeopleEnhance ProcessesDrive InnovationNurture RelationshipsDemonstrate LeadershipDeliver Results

CULTURALCOMMITMENT

A Way of Business, A Way of Life.

£500 BONUS is waiting for you Did you know that there is a £500 bonus

available to all staff for the successful

introduction of new business?

So if you have a contact in another

manufacturing company that you

believe would benefit from working with

ATS, simply contact Keith Edmonds on

kedmonds@advancedtech.com

www.advancedtech.com

Advanced Technology Services UK LtdUnit 4 BeechwoodCherry Hall RoadKettering Business ParkKetteringNorthamptonshireNN14 1UE

Phone: +44 (0)1536 311650

Email: info@advancedtech.com

Key Contacts

Managing DirectorDerek Hilldjhill@advancedtech.com

Sales & Marketing Keith Edmondskedmonds@advancedtech.com

Continuous ImprovementSteve McCarthysmccarth@advancedtech.com

Human ResourcesGemma TurnerGturner@advancedtech.com+44 (0) 1536 311657 - Direct+44 (0) 7527 289917 - Mobile+44 (0) 1536 416965 - Fax