Eliminating sources of maintenance losses

• US 8,170,893 B1
• Filed: 10/12/2006
• Issued: 05/01/2012
• Est. Priority Date: 10/12/2006
• Status: Active Grant

• Current Assignee: Sergio J. Rossi
• Original Assignee: Sergio J. Rossi
• Inventors: Rossi, Sergio J
• Primary Examiner(s): Boswell, Beth V
• Assistant Examiner(s): FEACHER, LORENA R
• Application Number:
  US11/548,924
• Time in Patent Office: 2,028 Days
• Field of Search: 705/7.11
• US Class Current: 705/7.11
• CPC Class Codes: G06Q 10/063 Operations research, analysis or management

Abstract

Processes and software are provided for eliminating sources of maintenance losses in machine intensive environments such as manufacturing, processing and assembly plants.

The processes and software include creating financial and work order metrics to trend maintenance variables, a process for creating work orders, a process for using alarms for integrating measurement technologies and spare parts, a process for managing repair and replacing activities and projects by improving documenting and communicating processes while involving users such as executives and senior managers.

Claims

1. A process for simultaneously addressing multiple sources of maintenance profits and losses, the process comprising:

a. entering, using a computer, historical data regarding one or more assets and if historical data is not available entering estimated data regarding the one or more assets;

b. classifying and calculating at least one Maintenance Profit &

Loss parameter for the one or more assets using said computer;

c. generating a ranking list of the one or more assets using said at least one Maintenance Profit &

Loss parameter;

d. developing and optimizing work order tasks based on the ranking list, wherein those one or more assets with the highest rank maintenance profit and loss have work order tasks developed from 5S for Machine/Maintenance (5S4M), 5S for Production/Process (5S4P), and measurement technologies (MT) that are larger in number of said work order tasks and are according to asset type of said at least one or more assets and further wherein those one or more assets with the lowest rank maintenance profit and loss have work order tasks developed from 5S4M/5S4P/MT that are lower in number of said work order tasks and are according to asset type of said at least one or more assets;

e. using a slope generated by trends in said measurement technologies by said asset type to trip alarms that identify problems, wherein the higher at least one asset is in said ranking list, the tighter the slope required to trip an alarm;

further wherein the lower at least one asset is in said ranking list, the broader the slope required to trip said alarm;

f. generating an integrative work order including at least said developed work order tasks, an integrative graph displaying said trends in said measurement technologies, said tripped alarms, and said at least one Maintenance Profit &

Loss parameter;

g. managing at least testing, trending, and repairs based on said integrative work order;

h. classifying said work order tasks according to scheduled or unscheduled repairs, consequences and task origins including Machine Process People (MPP);

i. using data from said work order for analyzing said multiple sources of maintenance profits and losses and generating tools for training, analysis and communication; and

j. using said computer for displaying a number of instructions and providing feedback for users to address said multiple sources of maintenance profits and losses.

2. A process of claim 1 wherein said entering historical data and estimated data regarding the one or more assets comprises:

a. machine and production related data;

b. critical components and their spare parts list;

c. production and machine assigned to operators and technicians; and

d. Maintenance Profit &

Loss parameters.

3. A process of claim 2 wherein said Maintenance Profit &

Loss parameters comprises;

a. classifying, forecasting and calculating probabilities of maintenance profits and losses (MP&

L);

b. classifying, forecasting and calculating probabilities of Hard MP&

L

c. classifying, forecasting and calculating probabilities of Soft MP&

L;

d. classifying, forecasting and calculating probabilities of Total MP&

L

e. using Total MP&

L to rank assets criticality;

f. classifying line, area, section, and plant MP&

L;

g. classifying Variant MP&

L;

h. classifying Universal MP&

L;

i. classifying Total MP&

L;

j. classifying Differential MP&

L;

k. classifying Max MP&

L;

l. classifying, forecasting and calculating the MP&

L of work order tasks; and

m. classifying, forecasting and calculating repair and replace activities into its repair or replace actual time components (RRATC).

4. A process of claim 1 wherein said classifying and calculating the at least one Maintenance Profit &

Loss parameter using said computer comprises;

a. deriving profits and losses caused from the times spent in each of the repair logistics and activities;

b. calculating the profits and losses caused by a breakdown;

c. calculating and forecasting Variant MP&

L, Universal MP&

L, Total MP&

L Differential MP&

L, Max MP&

L; and

d. calculating an individual contribution of each of the repair logistics and activities to time periods such as weeks, months, quarters, or years.

5. A process of claim 1 wherein generating the ranking list of the one or more assets using said at least one Maintenance Profit &

Loss parameter comprises;

a. an ascending or descending order listing assets according to said Maintenance Profit &

Loss;

b. line, area, section, and plant'"'"'s Maintenance Profit &

Loss;

c. probabilities of maintenance profit and losses (MP&

L); and

d. probabilities of Hard MP&

L

e. probabilities of Soft MP&

L.

6. The process of claim 1, wherein said 5S for Machine/Maintenance (5S4M) comprises:

a. shinning, whereas shinning means activities to make a machine or maintenance component or system clean by a technician;

b. simplifying, whereas simplifying means activities to make a machine or maintenance component or system simpler for technicians to repair or replace;

c. sorting, whereas sorting means activities to make a machine or maintenance components or system organized to be readily accessible for technicians;

d. standardizing, whereas standardizing means activities to make a machine or maintenance components or systems standard for a technician; and

e. statistic, forecasting and reliability functions (SFRF), whereas SFRF means activities that use the computer to predict and forecast failures, estimate profit and loss parameters, for a machine, or maintenance component or system.

7. The process of claim 1 wherein said 5S for Production/Process (5S4P) comprises:

a. shinning, whereas shinning means activities to make a production or process component or system clean by an operator;

b. simplifying, whereas simplifying means activities to make a production or process component or system simpler for technicians to repair or replace;

c. sorting, whereas sorting means activities to make a production or process components or systems organized to be readily accessible for technicians;

d. standardizing, whereas standardizing means activities to make a production or process components or systems standard for a technician; and

e. statistic, forecasting and reliability functions (SFRF), whereas SFRF means activities that uses the computer to predict and forecast failures, estimate profit and loss parameters for production or process components or system.

8. The process of claim 1, wherein said integrating a multiplicity of measurement technologies (MT) comprises:

b. using an ultrasonic alarm;

c. using a vibration alarm;

d. using a metal particles alarm;

e. using a temperature alarm; and

f. using a process parameters alarm.

9. The process of claim 1 wherein optimizing work order tasks comprises:

a. setting a quantity and type of 5S for machine/maintenance (5S4M) work order tasks based on asset criticality and profit and loss parameters;

b. setting a quantity and type of 5S for production/process (5S4P) work order tasks based on asset criticality and profit and loss parameters;

c. setting a quantity and type of measuring technologies (MT) work order tasks based on asset criticality and profit and losses parameters;

d. setting 5S4M, 5S4P and MT work order tasks frequencies based on asset criticality and profit and loss parameters; and

e. measuring and adjusting profit and losses generated from each work order task implemented.

10. The process of claim 1 wherein managing at least testing, trending and repairs on said work order comprises:

a. using the integrative graph of measurement technologies to observe said alarms;

b. using one or more tripped alarms to determine and confirm imminent wear or failure; and

c. using a wear or failure confirmation to request and manage said work order for repair and replace.

11. The process of claim 1 wherein classifying said work order according to scheduled or unscheduled repairs, consequences and task origins comprises:

a. time at which a breakdown occurred and details;

b. time maintenance took to answer production request;

c. time maintenance took to troubleshoot to find the source of breakdown;

d. time maintenance took searching for support, tools, instruments;

e. time maintenance took to complete the repair or replace activities;

f. time maintenance took to ready machine for production start up;

g. time production took to make a deliverable product;

h. time maintenance took to complete all details of repair and replace activities;

i. time maintenance took to complete all details of root cause failure analysis (RFCA);

j. time maintenance or production took to complete all details of 5Why analysis (5Y);

k. developing machine, people, processes (MPP) process for classifying task origin and intentions;

l. developing MPP metrics for determining origin of maintenance profit and loss;

m. classifying and measuring repair and replace actual time activities (RRATC); and

n. classifying tasks as per R&

R, R&

RP and measuring and improving types.