Speeding maintenance performance through time study

Abstract

As more than $300 billion spent on plant maintenance and operations, U.S. industry spends as much as 80 percent of this amount to correct chronic failures of machines, systems, and people. With machines and systems becoming increasingly complex, this problem can only worsen, and there is a clear and pressing need to establish comprehensive equipment management programs that incorporate the diverse considerations that are essential to minimizing risk and lead to effective maintenance. In a production or manufacturing environment, good maintenance engineering is necessary for smooth and safe daily plant operations. This research which was conducted at one of the worldwide well known Semi Conductor Company located at Kedah, Malaysia were drive subject to improve the effectiveness of preventive maintenance activities through lean approaches. Tools such time study, spaghetti diagram and FMEA were the main key tools and concept drive throughout this research. Machine Availability is the indicator used to evaluate the improvement expected for all the proposal took in placed. With the team effort and several proposal were addressed, Machine Availability able to be improved about 0.4% which lead to improvement of weekly preventive maintenance from 4 hours on actual observation to only 1 hours as new target. It also indirectly lead to the improvement of monthly preventive maintenance which may only require 4 1/2 hours instead of 5 1/2 hours of previous target. The result is currently practiced and team still looking for further opportunity to improve.