Corrugated Equipment – Production/Reliability Improvement
MANUFACTURING SOLUTIONS
Completion:
2007
Staff:
John Kravontka, CMRP
President/Project Director
Corrugated Equipment Production/Reliability Improvement North Haven, Connecticut
Client was experiencing a high frequency of equipment breakdowns, stoppages and qualityissues.
Downtime over 20%
Slow run speeds
Numerous maintenance issues
Unpredictable PM’s
No communications between operators and maintenance
Quality issues affecting converting equipment (down line)
F&O facilitated the client’s team (maintenance & operators) through the following:
Training on equipment evaluation
Basic measurements
Cleaning, inspections, repairs, modifications
Establishing basic system conditions
Setting up meaningful Daily Operator checks
Setting up Maintenance PM’s
Use of Predictive maintenance tools to locate bearing failures and electrical loose connections
These improvements were part of a TPM 5 Day Focused Improvement session.
Results:
9% increase in Corrugator output
31% drop in Maintenance downtime
16% drop in Maintenance occurrences
Shorter duration of mechanical downtime
34% decrease in Cart changeover time
7% increase in converting equipment productivity (down line)
ROI of 3 weeks
Improved morale/pride in work area