Improving maintenance work flow processes in a volatile assembly factory environment : maintenance people and processes, spares inventory, and equipment reliability

Abstract

Many manufacturing companies face significant challenges in maintaining their factory equipment in a cost efficient manner so as to provide reliable production capacity. CEI (Consumer Electronics, Inc., a pseudonym for an electronics marketing, sales, and assembly company that this work is based on) is no exception. The factory maintenance organization at CEI, similar to many other companies, had been relegated to the status of necessary evil, a cost center that was necessary but not always effective or efficient. Historically, the maintenance organization had been almost entirely reactive in its approach to maintenance. This study reviews many ideas for how CEI could, consistent with management objectives, become more proactive in its approach to maintenance. This work presents an investigation into the work flow processes inherent in CEI's factory maintenance organization and suggests improvements to the processes and the software infrastructure to support those processes that might be appropriate. Specifically the reactive (emergency) and preventative maintenance work processes are analyzed and suggestions to improve data integrity and to improve communication are presented - providing the maintenance technicians with better information with which to do their jobs.

(cont.) Improvements for factory spare parts management are also suggested describing how CEI could potentially improve its fill rate while holding significantly less inventory. The role of equipment analysis technology and materials analysis in predicting equipment reliability is also discussed.