The roadmap milestones set out the steps to systematically optimise current and then future operational capabilities. Each step builds on the previous one to deliver year on year improvement and step out products and services to lead the market.
Start with an honest assessment of how each level of the organisation use data as part of their work routine using the following 5 characteristics of data use.
- Basic data is captured and collated to satisfy financial reporting needs.
- Performance data is routinely captured and shared widely but not used by those who collect it. Gaps in data accuracy result in frequent ad hoc data capture activities to deal with issues as they arise.
- Data is used to set priorities, establish improvement targets and provide the insight to guide progress towards them.
- Data is used to understand cause/effect mechanisms and improve process performance.
- Data is used to optimise process capabilities and support delivery of step out products and services.
If the assessment is at level "a or b" in the above start with the using the digital ecosystem to identify problem hot spots. Create a small cross functional team to work on using data to establish basic condition standards and confirm the gains made.
Then use the analysis to reduce equipment wear rates and prevent the causes of human error.
If your shop floor data systems can't support this, use the project to connect up existing stranded data from PLC's etc or use smart sensors with cloud based software to provide the analysis.
In addition to reducing breakdowns, this team based action will improve collaboration between production and maintenance, encouraging new thinking and innovation.
Use this first project to formalise:
- What data to capture,
- How to do that,
- How to engage the workforce in using the new insights to improve performance,
- How to transfer the lessons learned across the business.
For assessments "c to e" pick your starting point on the road map milestones below and use this as a guide to establishing clear priorities and develop internal data analysis capabilities across all organisational levels.
|
Road Map Steps |
Data Analysis Priorities |
Actions to progress to next milestone. |
|
1 Taming Technology |
Analysis Theme: Break out of Reactive Firefighting Raise understanding of accelerated wear and cause/effect mechanisms. Systematic improvement as part of daily management. |
Release time by standardising core activities and reducing the causes of accelerated wear. |
|
2 Ratchet up performance |
Analysis Theme: Removing knowledge/skill gaps to raise standards and prevent problems reduce recurring problems. |
Simplify routine tasks, prevent misoperation and delegate core tasks to front line teams. |
|
3 Optimise |
Analysis Theme: Increasing Mean Time Between Intervention to drive down defects, improve yield, flexibility and process precision. |
Cross functional collaboration to enhance process control and customer added value gains. |
|
4. Strive for Zero |
Analysis Theme: Deliver new products and services in less time. |
Improving cross company collaboration to bring in new products and services that set the customer agenda |
Figure 1 TPM Roadmap Milestones
The TPM focussed improvement tools applied at each Roadmap Step benefit from the enhanced quality of feedback from Digital Notifications. This data combined with the use of systems modelling and machine learning analysis tools speeds up development of understanding about how to:
- Track performance against Normal condition standards and trigger the response needed to deal with abnormal conditions.
- Optimise planned maintenance windows
- Refine process parameters to deal with factors such as variation in material quality or environmental conditions.
The digital ecosystem can also be used to coordinate the development of:
- Best practice work routines,
- Compliance/feedback re problem hot spots,
- Contamination control,
- Work instruction review cycles,
- Fault finding and problem prevention,
- Engineering Change Management,
- Connected worker low/no code micro service apps,
- Learning plan development and application.
The automation of data capture and analysis around these topics accelerates progress towards zero breakdowns and no touch production.
Making It Happen
Change begins with leadership. Deciding how to steer the ship is the first step.
The TPM roadmap programme builds a network of committed internal stakeholders to develop and refine new approaches on a manageable scale.
It does that by setting out the steps to change the shop floor reality and define the blueprint for change to streamline plant and workflow ecosystems to deliver a broad organisational transformation.
How DAK Can Help
The journey to transformation is complex so external support can be invaluable in developing robust internal capabilities.
We can provide expertise to blend systematic improvement with the innovative power of machine learning and AI, all while keeping the human element at the forefront of progress.
Our accelerator workshops, internal training academy programmes plus consultancy advice and guidance are designed to do just that.
