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Raul Martins

Congratulations! You've been assigned the task of reducing the assembly issues of a maintenance team.

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Hello everyone,

As mentioned in the title of the topic, congratulations!

You, as an experienced Maintenance and Reliability professional, were assigned to a new task:

     Reduce the assembly issues of a maintenance team.

 

Unfortunately, as the world is going through tough times, which includes your company, your budget to invest in training and improvements is really low and you have to look for cheap alternatives that will bring a positive outcome.

That being said, how would you tackle this issue?

Improve the process? Work instructions? Internal training?

Well, it is up to you. Just bear in mind that you need to be creative and really low-cost.

 

Also, Don’t forget about explaining your strategy and how this would solve such issue.

 

Regards,
Raul Martins

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Reducing the Assembly Issue of a Maintenance Team.

First step to address the issue is to carry out Root  Cause Analysis of the Current Issue.

Haven identify the Problem say Improper assembly and lack of precision assembly and maintenance.

Secondly,Access the knowledge and skill gap of the technician to determine the skill and experience gap.

Haven determined the gap in skill and knowledge, arrange for in-house training on the job training in conjunction with human resources department to provide the necessary resources and environment to the program.

On the job training content, I will ensure detailed drawing information of the assembly plant and equipment is available for demonstration.

The training should focus precision assembly and maintenance.

Sensitize the top management that maintenance is not cost  center but value cost if the right technology and materials is provided. This will result to profit in the near future. This can be done through data. 

On 5/16/2020 at 9:34 AM, Raul Martins said:

Hello everyone,

As mentioned in the title of the topic, congratulations!

You, as an experienced Maintenance and Reliability professional, were assigned to a new task:

     Reduce the assembly issues of a maintenance team.

 

Unfortunately, as the world is going through tough times, which includes your company, your budget to invest in training and improvements is really low and you have to look for cheap alternatives that will bring a positive outcome.

That being said, how would you tackle this issue?

Improve the process? Work instructions? Internal training?

Well, it is up to you. Just bear in mind that you need to be creative and really low-cost.

 

Also, Don’t forget about explaining your strategy and how this would solve such issue.

 

Regards,
Raul Martins

Reducing the Assembly Issue of a Maintenance Team.

First step to address the issue is to carry out Root  Cause Analysis of the Current Issue.

Haven identify the Problem say Improper assembly and lack of precision assembly and maintenance.

Secondly,Access the knowledge and skill gap of the technician to determine the skill and experience gap.

Haven determined the gap in skill and knowledge, arrange for in-house training on the job training in conjunction with human resources department to provide the necessary resources and environment to the program.

On the job training content, I will ensure detailed drawing information of the assembly plant and equipment is available for demonstration.

The training should focus precision assembly and maintenance.

Sensitize the top management that maintenance is not cost  center but value cost if the right technology and materials is provided. This will result to profit in the near future. This can be done through data. 

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Hello everyone 

Firstly is doing Root Cause analysis to understand the the causes of assembly causes. From the RCA I will then get a better understanding the issues and pin pointing underlining issues. Training and coaching of of our employees on precision maintenance that would assist improving our maintenance. Also developing work instructions to the maintenance teams on assembly issues. 

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Maintenance team are usually not involved in production assembling of equipment. Minimising reassembling issues actually begins from the earlier stage of disassembling of used equipment.

In new equipment, all components are new and it is much easier to strip down a new unused equipment ( if you want to do reverse engineering and record the manufactured original measurement) and reassembling back. Used equipment disassembling is a different ballgame.

If a technician has no specific experience in disassembling of a particular equipment, but familiar with general good practices of disassembling ( including inspection, recording as-found settings and marking adjacent components), he could still be able to overhaul the equipment. However, it would be advisable to obtain a cross section drawing and study what components make up the equipment and the features and material of each components. Features for aligning and mating should be identified. It would be good to take that copy of the cross sectional drawing and colour each components in different colours. Below is an example. This is my first condition for any technician to be allowed to lead in the overhauling work, that is able to colour such drawing correctly. From the drawing the technician can determine the correct and proper sequence of dismantling, what jigs and tools are needed, and the cares to be taken.

817266089_PUMPXEMC44LKXA-16-0000Color.thumb.png.4cc0f17003156e128749262df9e38cd9.png

After completion of the disassembling, each and every used component must be inspected visually and dimensionally, for imperfections i.e wears, distortion, etc. Even new component must be inspected and measured to determine the likely fits and clearances and possible mismatch during reassembling. Worn parts may needed to be rebuilt. Any damages, from the disassembly must also be corrected. Each component must be handled with care as dents can create problems during assembling. [ There is no 100% guarantee that new parts even from reliable trusted source can fit perfectly to adjacent components that are reused). If you are reusing components, an experience technician can foresee the issues that he is likely to face during reassembling.

Whatever findings during disassembly, the inspection of old or new parts,the refurbishment works on components can already assist in foretelling the likely issues during reassembling.

Cleanliness during an reassembling is extremely important. Fitting should always be carried out with care in accordance with Good Engineering and Industrial Practices, especially when power tools are employed. There are so many do and don't in reassembling of equipment to obtain a flatten reliability bathtub curve for that equipment. Simply assuming that  overhaul is just parts-changing often lead to random failure.

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16 hours ago, Andronica Kwapeng said:

Hello everyone 

Firstly is doing Root Cause analysis to understand the the causes of assembly causes. From the RCA I will then get a better understanding the issues and pin pointing underlining issues. Training and coaching of of our employees on precision maintenance that would assist improving our maintenance. Also developing work instructions to the maintenance teams on assembly issues. 

@Andronica, Thanks for your contribution.

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1 hour ago, IrWCSoh said:

Maintenance team are usually not involved in production assembling of equipment. Minimising reassembling issues actually begins from the earlier stage of disassembling of used equipment.

In new equipment, all components are new and it is much easier to strip down a new unused equipment ( if you want to do reverse engineering and record the manufactured original measurement) and reassembling back. Used equipment disassembling is a different ballgame.

If a technician has no specific experience in disassembling of a particular equipment, but familiar with general good practices of disassembling ( including inspection, recording as-found settings and marking adjacent components), he could still be able to overhaul the equipment. However, it would be advisable to obtain a cross section drawing and study what components make up the equipment and the features and material of each components. Features for aligning and mating should be identified. It would be good to take that copy of the cross sectional drawing and colour each components in different colours. Below is an example. This is my first condition for any technician to be allowed to lead in the overhauling work, that is able to colour such drawing correctly. From the drawing the technician can determine the correct and proper sequence of dismantling, what jigs and tools are needed, and the cares to be taken.

817266089_PUMPXEMC44LKXA-16-0000Color.thumb.png.4cc0f17003156e128749262df9e38cd9.png

After completion of the disassembling, each and every used component must be inspected visually and dimensionally, for imperfections i.e wears, distortion, etc. Even new component must be inspected and measured to determine the likely fits and clearances and possible mismatch during reassembling. Worn parts may needed to be rebuilt. Any damages, from the disassembly must also be corrected. Each component must be handled with care as dents can create problems during assembling. [ There is no 100% guarantee that new parts even from reliable trusted source can fit perfectly to adjacent components that are reused). If you are reusing components, an experience technician can foresee the issues that he is likely to face during reassembling.

Whatever findings during disassembly, the inspection of old or new parts,the refurbishment works on components can already assist in foretelling the likely issues during reassembling.

Cleanliness during an reassembling is extremely important. Fitting should always be carried out with care in accordance with Good Engineering and Industrial Practices, especially when power tools are employed. There are so many do and don't in reassembling of equipment to obtain a flatten reliability bathtub curve for that equipment. Simply assuming that  overhaul is just parts-changing often lead to random failure.

Thanks for your contribution. Your point focuses on precision assembly and maintenance. 

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Hi @Engrjoe and @Andronica Kwapeng,

Great replies!

As you mentioned, in addition to training, it is extremely important to have specific information about the pieces of equipment easily accessible for the maintenance technicians.

No one is required to have everything in their minds when they are assemblying an asset, so having solid work instructions, up-to-date drawings and bill of materials, detailing the steps of each task is a vital part on solving such issue.

 

Regards,

Raul Martins

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Hi @IrWCSoh,

I haven't seen this colour coded drawing before. I like it, It seems to be really interesting and handy.

Congratulations!

 

Regards,

Raul Martins

 

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Posted (edited)

Hello to All,

 

Please find some feedback from my side also. 

To begin with, the creation of detailed work instructions with clear drawings and step must be the base of the maintenance team Knowledge. Clear and structured processes can assist the new technicians and reduce the need of general training. Also, the inhouse -on the Job training will  help. Create with the HR, internal training with training material and produce value from the experienced technicians in the maintenance team. Give them the tools and the environment to spread their knowledge inside the team.

For big companies training between countries could be established or even Blogs for the technicians to stress their questions  and exchange knowledge. 

Moreover, you can push the procurement department to include training as an additional service when buying a new machine, reducing the training cost .

In my company we are starting to using Smart glasses in the maintenance Job in order to connect remotely  in real time the technicians with the experts  and reduce the need for special training for the technicians. 

Also, learn what is the actual need of the your maintenance knowledge and focus the training in these sectors . One strategy is to build special teams  that are trained for specific tasks and use them when the task is needed.

 

I hope my feedback is helpful to you.

Edited by NikosPant

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Hi @NikosPant,

I also see the use of detailed work instructions and internal training are an excellent way to reduce rework levels at low cost, as well as an opportunity to recognize experienced technicians.

Companies usually have several technicians are a cut above on specific tasks that could be training other technicians to improve their skills.

In regards to the Smart glasses, the experts are staff members of the equipment supplier or engineers that provide such support?

 

Regards,

Raul Martins

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4 hours ago, Raul Martins said:

Hi @NikosPant,

I also see the use of detailed work instructions and internal training are an excellent way to reduce rework levels at low cost, as well as an opportunity to recognize experienced technicians.

Companies usually have several technicians are a cut above on specific tasks that could be training other technicians to improve their skills.

In regards to the Smart glasses, the experts are staff members of the equipment supplier or engineers that provide such support?

 

Regards,

Raul Martins

The connection could be either with engineers from the maintenance team or with OEM (if there is a technical support contract )

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