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Maintenance Plans and Tasks:Eliminating Non-Value Added Maintenance
Activities for Improved Reliability
Robert WigginsShowa Denko Carbon, Inc
Maintenance Planning and Scheduling Supervisor
•Robert Wiggins is a graduate of Trident Technical College with a diploma in the Industrial Electrical program and holds a BS degree in Business Administration/Management from Limestone College. •He has over 27+ years experience with Showa Denko Carbon, Inc. (SDKC) and working in industrial maintenance and manufacturing. •Robert joined SDKC in 1984 as a shift electrician. He has served as a maintenance supervisor, planner and planner-scheduler. •Robert currently serves as the maintenance planning and scheduling supervisor and is responsible for managing four maintenance planners, and the maintenance planning and scheduling activities for 37 technicians and numerous contractor services. •Robert is actively involved with updating and creating maintenance items, tasks, and maintenance plans, as part of a reliability effort to establish an SAP database maintenance library for routine and corrective type maintenance activities.
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GLOBAL CAPABILITY
QUALITY SERVICE RELIABILITY
GRAPHITE ELECTRODES
GRANULAR GRAPHITE
FINE CARBONS
MARKET PLACE
QUALITY SERVICE RELIABILITY
Large-Diameter Ultra High Powered Graphite Electrodes used in the Electric Furnace Steelmaking
Industry
GRAPHITE ELECTRODES
QUALITY SERVICE RELIABILITY
QUALITY SERVICE RELIABILITY
QUALITY SERVICE RELIABILITY
•Friction Materials•Lubricants•Conductive Coatings•Carbon & Graphite Shapes
HIGH PERFORMANCE GRAPHITE FOR AUTOMOTIVE & INDUSTRIAL APPLICATIONS
GRANULAR GRAPHITE
QUALITY SERVICE RELIABILITY
GRAPHITE TECHNOLOGIES FOR ADVANCED ENERGY SYSTEMS
•Vapor Grown Carbon Fiber•Shape Controlled Micro Graphite Powder•Impervious Graphite Composite Plate•Ultra Fine Graphite Powder
FINES CARBON
Construction of Ridgeville plant
Shipment of first 24” electrodes
Shipment of first 28” electrodes
Acquired by Showa Denko KK
PIP plant expansion
ISO9002 registration
KDAC plant expansionOver $100 million sales
Shipment of first 30” electrodes
Shipment of first 32” electrodes
1982 1983 1985 1988 1990 1995 1996 1997 2008
Over $200 million sales
2006
QUALITY SERVICE RELIABILITY
CORPORATE HISTORY
•Petroleum Needle Coke
•Binder Pitch
•Iron Oxide
•Stearic Acid
Petr
oleu
m R
efine
ryD
istil
latio
n Pr
oces
s
Stee
l Pic
klin
g Pr
oces
s
RAW MATERIALS
QUALITY SERVICE RELIABILITY
•Iron Oxide
Mix
Extrude Bake Impregnate
RebakeGraphitizeMachine
FormulateNeedle Coke StorageScreen
Binder Pitch
Petroleum Pitch
QUALITY SERVICE RELIABILITY
PROCESS OVERVIEW
QUALITY SERVICE RELIABILITY
SAP RELEASE 4.7
Maintenance Plans and Tasks:Eliminating Non-Value Added Maintenance
Activities For Improved Reliability
Robert WigginsShowa Denko Carbon, Inc
Maintenance Planning and Scheduling Supervisor
Preventative Maintenance Plans and Tasks:
•Eliminating Waste
•Increasing Value and Reliability
QUALITY SERVICE RELIABILITY
Inspect???
Check???
Verify???
Ensure???
QUALITY SERVICE RELIABILITY
Inspect???
Check???
Verify???
Ensure???
QUALITY SERVICE RELIABILITY
Update Procedures
Combine Tasks
Adjust Frequencies
Change Crew Assignments
QUALITY SERVICE RELIABILITY
Update Procedures
Combine Tasks
Adjust Frequencies
Change Crew Assignments
QUALITY SERVICE RELIABILITY
Maintenance Frequencies
Poorly Identified
Duplication Of Maintenance
Tasks.
Incorrect Labor &
Craftsmen Identified
Maintenance Tasks
Assigned With No
Procedures
Shutdown Requirements
Not Adequately Identified
Production Equipment Not
Properly Prepared For Service
QUALITY SERVICE RELIABILITY
First Pass To Pick The Low Hanging Fruit:
Review All Maintenance Plans/Task To
Determine The Actual Job Requirement.
Second Pass: Review All Maintenance
Plans/Task Procedures For Duplications. 15-20% Of PM
Tasks Issued To Maintenance
Technicians Are Most Likely
Performed By Operators As Part
Of Their SOP
QUALITY SERVICE RELIABILITY
Change!!!
Replace!!!
Adjust!!!
Document!!!
QUALITY SERVICE RELIABILITY
Change!!!
Replace!!!
Adjust!!!
Document!!!
QUALITY SERVICE RELIABILITY
Review Tasks For Measurement Points
and Adjustments. Make certain This
Information Is Documented In The
PM Text.
Run To Failure: Carrying Critical Spares And Long
Lead Items. Some Equipments May Be More Cost Effective To Allow To Run to Failure Than Spend
Labor on Inspections.Inspecting Belts, Sheaves, Chains,
Sprockets – Versus Periodic
Replacement Based On Mfg Data And Known Failure
Rates
QUALITY SERVICE RELIABILITY
What Do You Expect To Gain From Your Preventative Maintenance Program?
• Safety: Safety And Health Is Priority For People And Equipment
• Visibility: Well Maintained Equipment Looks Good• Availability: Equipment Runs On Demand• Reliability: People – Processes – Equipment• Maintainability: Ease Of Maintenance • Profitability: Low Maintenance Cost Per Production Unit • Sustainability: Provides Improved Maintenance Program For
Future Workforce
QUALITY SERVICE RELIABILITY
•Maintenance Item Descriptions Should State The Expected Outcome Of The Order
•Item Descriptions Should Be Standardized For Consistency
QUALITY SERVICE RELIABILITY•Maintenance Task Operations Should Be Titled To Indicate The Exact Task Assignment
•Tasks Should Be Broken Out By Craft And By Sequence Of Order
•Each Operation Has Correct Estimate Of Labor Required
QUALITY SERVICE RELIABILITY
QUALITY SERVICE RELIABILITY
Equipment Type
Number of
Equipments
Number of
Maintenance
Orders Issued
Man-
hours/
Orders
Total Cost @
$51.00/hr Materials Total
Bake Furnace
Zone Fans @
Quarterly
Inspections 48 384 2 $39,168.00 none $39,168.00
Bake Furnace
Zone Fans @ 2-
Year Belt
Replacements 48 48 7 $17,136.00 $3936.00 $21,072.00
SAVINGS $18,096.00
QUALITY SERVICE RELIABILITY
Equipment Type
Number of
Equipments
Number of
Maintenance
Orders Issued
Man-
hours/
Orders
Total Cost @
$51.00/hr Materials Total
ID Fans @ Quarterly
Visual Inspections 12 96 1 $4,896.00 none $4,896.00
ID Fans @ 2-Year
Belt Replacements 12 12 2.5 $1,530.00 $1600.00 $3,130.00
SAVINGS $1,766.00
QUALITY SERVICE RELIABILITY
Equipment Type
Number of
Equipments
Number of
Maintenance
Orders Issued
Man-hours/
Orders
Total Cost @
$51.00/hr Materials Total
Pre-heater Fans
@ Quarterly
Inspections 8 64 1 $3,264.00 none $3,264.00
Pre-heater Fans
@ 2-Year Belt
Replacements 8 8 2 $816.00 $160.00 $976.00
SAVINGS $2,288.00
QUALITY SERVICE RELIABILITY
QUALITY SERVICE RELIABILITY
QUALITY SERVICE RELIABILITY
Purpose Statement: Why is job being requested
Special tools and Equipment
Drawings
QUALITY SERVICE RELIABILITY
Safety Procedure
Maintenance Procedure
QUALITY SERVICE RELIABILITY
Maintenance Procedure Details Exact Requirements For Completing Task
QUALITY SERVICE RELIABILITY
Maintenance Procedure
QUALITY SERVICE RELIABILITY
Equipment Checkout
Housekeeping
QUALITY SERVICE RELIABILITY
Materials
QUALITY SERVICE RELIABILITY
What is a Maintenance
Task?
QUALITY SERVICE RELIABILITY
Anything pertaining to the necessary basic support and repair
of equipment.
In SAP: A maintenance task is any single maintenance activity.
What is a Maintenance
Task?
QUALITY SERVICE RELIABILITY
Tasks Such As:– Lubrications– Infrared Thermo Graphics– Vibration Analysis– Inspections– Corrective Type Repairs
• Electrical - Replacement of motor• Mechanical – Replacement of gearboxes• Mobil - Replacement of batteries• HVAC – Replacement of filters• Welding - Containers
What is a Maintenance
Task?
QUALITY SERVICE RELIABILITY
Tasks Such As:– Adjustments– Rebuilds– Predictive Monitoring & Analyzing– Wear Based Component Replacements
• Sheaves / Belts• Sprockets / Chains• Shaft Seals• Armor Plates
What is a Maintenance Task?
QUALITY SERVICE RELIABILITY
Maintenance Tasks Importance?
•Write maintenance task to document the knowledge acquired by your senior maintenance technicians, planners and staff before they retire
• Write maintenance tasks to reduce “reinventing the wheel”
• Knowledge Transfer
• Planners and Technicians can issue orders from tasks quickly
QUALITY SERVICE RELIABILITY
• Write maintenance tasks to help bring your new maintenance force up to same level of expertise as existing maintenance personnel and quickly reduce learning curve.
• Write maintenance tasks to eliminate safety issues for employees and equipment.
• Reduces unexpected incidents.
• SAFETY FIRST!!
QUALITY SERVICE RELIABILITY
Maintenance Frequencies
Properly Aligned
Correct Labor &
Craftsmen Identified
Maintenance Tasks With
Well Defined Procedures
Duplication Tasks
Eliminated
Shutdown Requirements
Properly Identified
Production Operations
Established On Maintenance
Plans To Properly Prepared For
Service
QUALITY SERVICE RELIABILITY
Thank You for your attention and interest!
Questions?