Juan is a process engineer with a decade of experience helping CPG manufacturers implement continuous improvement processes. In his latest role he found himself working at a small division of a large national food manufacturer that was just taking its first steps towards lean manufacturing and operational excellence.
Juan’s goal was to support the implementation of a lean manufacturing system into his new employer’s plant. To do that he needed data on production, productivity, and other general metrics and inputs required for OEE calculations.
For Juan to help, he needed data.
Monin was drowning in paper and looking for a system that would ensure compliant workflows and automate KPI reporting insights to inform continuous process improvement, all without overwhelming operators. Weever started with Production Readiness Reports at one location and within 5 months was used across departments and all facilities in North America. The main benefit Monin realized was time savings, which resulted in a cascading positive impact, including faster production lines and enabling managers to focus less on report administration and more on product quality, abnormality reporting, and overall facility improvement.
Program performance has increased by over 500% with over 50,000 5S, CIL and Centerline submissions since launch.
Complicated manual processes, data entry, messy paper forms or complicated spreadsheets can doom your new Autonomous Maintenance program to failure. Fortunately, Industry 4.0 and digitization provide us with many new tools to help make the implementation and execution of AM much easier.
Here are some of the best practices and core challenges we’ve found helping massive global organizations, as well as regional manufacturers, to reap the benefits of Autonomous Maintenance over the last decade.
Deciding that you’d like to implement Autonomous Maintenance in your plant is a great first step towards promoting a more efficient and profitable plant. Now you’re faced with the real challenge – how to begin?
When properly implemented, AM can have a massive impact on the efficiency and profitability of a factory by reducing downtime, unplanned stoppages, while increasing OEE. The basic promise of AM is that it “outsources” simple maintenance tasks to operators which relieves maintenance teams to focus on more proactive concerns.
Autonomous Maintenance, or AM, is part of the Total Productive Maintenance (TPM) school of Lean Manufacturing. It is one of the 8 TPM pillars which aims to increase the productivity of a plant in a sustainable way.
Before you being rolling out your Behavior-Based Safety Observation program, you should consider the following questions. Determining the answers to these questions will ensure a flawless rollout and save time and headaches down the road.
The almost century-long history of Behavior-based safety began with research conducted by Herbert William Heinrich in the early thirties. Mr.Heinrich worked for Traveler’s Insurance Company in the early thirties. He reported that roughly 90% of all accidents, injuries, and illnesses were the result of what he called “worker errors.”*