Mission
80% OPE (Overall Plant Efficiency).
90% OEE (Overall Equipment effectiveness).
100% in delivering the goods to costumers.
Work in accident free environment.
Develop Multi-skilled and flexible workers.
Higher confidence level among the employees
Work place cleans, neat and attractive.
Favourable change in the attitude of the operators.
Achieve goals by working as team.
Share knowledge and experience.
Strategic Goal
By implementing CLT (A maintenance tool) in the manufacturing industries.
To reduce manufacturing cost
To Improve the OEE (Overall Equipment Efficiency
To minimize the manufacturing losses (Downtime loss, Speed loss and Quality loss)
What is CLT ?
CLT is a basic medical science for machine in manufacturing. It is a simple tool to keep the manufacturing plant in a healthy state which can deliver at maximum efficiency.C: Cleaning – Eliminating dirt, dust, exposing all abnormalities, correcting minor flaws and establishing basic equipment condition.L: Lubricating – Reduce the Friction, Heat Generation, Overloading.T: Tightening - It only takes one loose bolt to start a chain of reaction of wear and vibration, as a machine vibrates slightly, other bolts work loose, vibration feeds on vibration, the equipment starts to rattle and shake, tiny cracks widen into gaping splits, parts become damaged and the result is major breakdown.
Introduction of CLT
Manufacturing Maintenance Operations Design Engineering
Plant and Site Management Project Engineering Engineering Inventory and Stores
In order to properly understand the impact of CLT, it is necessary to establish a definition. CLT (Cleaning/Lubricating/Tightening) is maintenance activities that are productive and implemented by all employees. CLT involves everyone in the organization from operators to senior management in equipment improvement. It encompasses all departments including:
Cost-Benefit Strategic Goals
Productivity 100-200% increases 50-100% increase in rates of operation.500% decrease in breakdowns Quality 100% decrease in defects.50% decrease in client claims Costs 50% decrease in labour costs. 30% decrease in maintenance costs 30% decrease in energy costs
Inventory 50% reduction on inventory levels.100% increase in inventory turns Safety Elimination of environmental and safety violations Morale 200% increase in suggestions Increased participation of employees in small group meetings
CLT Philosophy
Old Attitude“I operate, you fix.”“I fix, you design.”“I design, you operate.”
CLT Attitude“We are all responsiblefor our equipment.”
Management…Operators….Maintenance…Engineers…EVERYONE!
High Manufacturing Cost Phenomena
Machine
Machine breakdown
No Cleaning
•Rusting Occurs•Foundation Fixers loose•Misalignment•Vibration
•Generation of heat•Deformation of material property•High Friction•Extra load on Machine
•Misalignment•Vibration
No Lubrication
Availability lost•Machine Time Lost•Design parameters Lost•Speed Efficiency Lost
Process Efficiency Lost•Low production•Low Operators Confidence•Low OEE
Quality Lost •Loss of Raw Material•Loss of Manpower due to Rework•Low production•No customer Satisfaction on product quality & delivery
High Manufacturing Cost
No Tightening
6 Manufacturing Looses
OEE Calculation
Big Idea
Reducing the manufacturing cost by increasing the equipment efficiency
Getting operators involved in maintaining their own equipment and emphasizing proactive and preventive maintenance will lay a foundation for improved production (no breakdowns, stops and defects)
Operators need to develop ownership of their equipment, and become full partners with Maintenance so that they can perform as a tight-knit team to create maximum equipment effectiveness.
There are two components to this attack on waste — Asset care and CLT maintenance. These components denote the close collaboration between those who operate the machine and those who maintain the machine, both of which drive up availability while driving down costs.
How to Sustain CLT
Implementation of CLT
The implementation of CLT is necessary to increase the sense of ownership of equipment among the operators and developing their interest in work. The goal of increasing production can be achieved by active participation of operators. 10 step for implementation of CLT.
1. Announcement of CLT and top management commitment2. Outline a detailed master deployment plan 3. Classification and Responsibly of daily maintenance.4. Launch a formal training program for selected team5. Develop a CLT maintenance program for operators.6. Pilot Team building7. Identification of Tools & Cleaning Material required at different
station.8. Establish basic CLT policies and quantifiable goals9. Develop a preventive maintenance plan10. Follow ups and Continuous improvement
Classification and Allocation of Maintenance tasks
Target Technique Activity Prod. Maint.
Overall
equipment effectiveness at least 85%
Maintenan
ce activities
Prevent Deterioration Measure Deterioration
Restore Deterioration
Normal OperationCorrect Operation O Correct Adjustment O
Daily Maintenance
Cleaning-expose and deal with flaws
O
Lubricating O Tightening O Check deterioration and condition of use daily O Minor servicing O
Periodic Maintenance
Periodic Checking O OPeriodic Inspection (Testing) O Periodic Servicing O
Predictive Maintenance
Trend Inspection O Medium-Interval and long-interval servicing O
Breakdown Maintenance
Prompt rapid detection of abnormalities, prompt action and reporting O ORecurrence prevention
O O
Emergency repairs
O
Improvement
activity
Corrective Maintenance
(Improve reliability)
Simplification O OLoad leveling O OImprove control precision
O O
Improve Maintainability
Develop condition monitoring equipment and techniques
O O
Improve inspection work
O
Improve servicing work O Improve servicing quality O
Reports
% Improvement in Availability.
% Improvement in Performance.
% Improvement in Quality. % Improvement in OEE/OPE. % Reduction in maintenance
cost. % Reduction in
Manufacturing cost.
CLT effectiveness indicators
Effectiveness Report on Indicator
ManagementOperating Profit Ratio of operating profit to gross capitalCost Reduction Equipment Investment EfficiencyLabour productivity Plant / labour ratio
Plant Effectiveness Availability % Performance %Quality % OEE % (Overall Equipment Efficiency)
QualityProcess Defect rate No. of warranty ClaimsCost of Process defect Value of Warranty ClaimsNo. of Process Defect Passed
Overall Yield
Energy SavingElectricity Consumption Water ConsumptionFuel Consumption Lubricant/Fluid ConsumptionSteam Consumption Auxiliary material Consumption
MaintenanceFailure Frequency Unit maintenance costFailure severity rate PM achievement rateEmergency maintenance rate
Overall Maintenance cost rate
Health, Safety and Environment
Accident frequency No. of danger points spotted by safety patrols
Accident severity rate No. of improvements made to dangerous work
No. of near-miss detected No. of accidents requiring time off workAnalysis of CLT Results with baseline yearly
Cost Reduction Labour productivityVariable production cost No. of failuresFixed production cost No. of major failures per period
Thank You