Post on 10-Mar-2016
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The monthly newsletter for ATS
ProActive2013 SEPTEMBER ISSUE
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Lean MaintenanceReducing waste
and cost
02
Lean maintenance programmes focus on driving efficiencies within the asset management and maintenance areas of manufacturing operations. As with all lean activities it is a journey and not a destination - the continuous improvement of an evolving process. Toyota, who have been applying lean for over 95 years continue to focus on lean maintenance as a priority as they recognise its impact on the smooth flow of operational lines. Lean maintenance is often referred to as Total Preventative or Total Predictive maintenance.
Many organisations that have been implementing Lean for decades are only now giving maintenance the attention it deserves. Those new to the adoption of lean should mark it as a top priority. Efficient maintenance programmes can drive significant improvements to productivity and process improvements, resource efficiencies and importantly significant financial benefits.
Advanced Technology Services provide maintenance solutions to the world’s largest manufacturers such as Caterpillar, Eaton, Honeywell, Dell and Ford. They have identified ten critical steps for implementing
a successful lean maintenance programme
Step 1
Apply organisation to the work areas
Utilising Five S principles within the
maintenance area will provide a sound
basis for identifying value and waste
within the maintenance process.
Step 2
Identify Value Streams and Strategy Maps
Understanding the value streams will help
you identify which activities add value and
which do not and can therefore be removed.
Strategy maps map the lean activities with
the companies overall strategic goals.
Step 3
Optimise Planning
Implementing and utilising maintenance
good planning and project management
will drive significant efficiencies and
improvements within maintenance activities
Step 4
Prioritise, repair and refurbish
In applying lean maintenance you are
looking to reduce waste, cost and improve
productivity. To achieve this it is important to
get both plant and maintenance equipment
to a good standard and then maintain it.
In the news Lean maintenance Reducing waste and costs
03
Step 5
Implement predictive strategies
Predictive maintenance provides a forecast
schedule of planned maintenance activity
based on historic data. Predictive strategies
deliver considerable cost savings and
improve asset longevity and they are
shown to significantly improve safety.
Step 6
Track metrics
Critical to the success of any lean
programme is the need to track key metrics.
They will provide information to identify the
most appropriate projects and can justify
expenditure when required. ATS use the
following in each of their factories to steer lean
maintenance: Key performance indicators
(KPI’s); Overall equipment effectiveness (OEE)
and Mean Time Between Failures. (MBTF).
Step 7
Perform Root Cause Analysis (RCA)
RCA is a method of problem solving that
establishes the fault or cause of a problem.
It is frequently used within the manufacturing
operations and should also be applied in
maintenance to establish machine failure
or break-downs.
Step 8 Employ the tools of Six Sigma
Most organisations will use a computerised
maintenance management software (CMMS)
which can be used for preliminary six sigma
evaluation. Once useful data is gathered
within the CMMS tracking failure causation,
Six Sigma initiatives can be instigated.
Step 9 Evaluate Performance
As with any project or activity it is essential
to report on key financial and strategic
measures to justify the continuing
investment in the process.
Step 10 Continually improve
As mentioned previously, lean is not a
destination but a journey of continuous
improvement, new or changing assets will
mean a need to continuously update the
programme of lean activities.
Focusing on an effective lean maintenance
strategy will pay off both financially and in
terms of productivity. It will improve work
place satisfaction and improve safety. This is
the core of manufacturing competitiveness.
In the news Lean maintenance Reducing waste and costs
Kulwinder Bhamber, Supply Chain/
Technician at Brierley Hill, was called out
to look at a breakdown on a machine
when he noticed an issue with the
locking mechanism for the tooling.
The spring loaded mechanism is
supposed to lock the tooling into position
for when material is required to be
punched. Without this locking mechanism
in place, the tooling can move freely and
the materials will vibrate, putting both the
machine and operator at risk.
Kulwinder locked off the machine and
assessed the job to get to the spring loaded
mechanism, which required the
Chris Smith - Site Supervisor, awards Andy Kulwinder Bhamber, Supply Chain/Technician
main head, to be stripped down.
He found that the spring inside had
snapped, so a suitable replacement was
fitted and the mechanism was tested and
confirmed as serviceable. This was an
excellent identification of an issue that
could affect customer safety, and a
well-managed solution was engineered.
Live safetyOur first priority
04
Kulwinder Bhamber - Locking mechanism
HAZARD OF THE MONTH
WINNER
During a reactive maintenance work
order, Julian Burrows (ATS Technician at
Havant) was required to look into a test
rig electrical cabinet to check for tripped
overloads, and visually observe input and
output indicators. Upon inspection, a strong
burning smell was immediately obvious
and an overheated wire was identified.
Julian immediately powered down and
locked out. The fuse holder was too hot to
touch so was left to cool, before the fuse
holder and damaged wiring was replaced.
This situation would have only gotten worse
and could possibly have caused a short
circuit and fire hazard had it not been
found. Great work Julian.
05
Proportional Test Rig asset #6511
Before
After
06
ATS Wolverhampton Diamond award for safety
Andy Plant - ATS Supply Chain Specialist and Julian Budd CAT Facilities Manager
“This is a great achievement for both ATS and Caterpillar, showing how we are both working in unison to improve our safety standards, this is just another great example of the importance of the great safety culture within the ATS business.”
07
Delight customers
Congratulations to ATS at Wolverhampton on
achieving a Diamond award for Safety.
All contractors on site, including ATS, have gone
731 days with no recordable incidents. Since ATS’
inauguration on 1st August 2010, there have been
no recordable accidents. This is 1122 days of safe
working within the department. The company’s
primary cultural commitment is ‘Live Safety’,
which is implemented in several ways, including:
• Daily safety talks
• Dedicated on sight H&S representative
• Safe working practices including things such
as LOTO and PTA
• Qualified and conscientious work force
• Adherence to H&S laws and PPE requirements
• Safety observations and safety training
08
Developing people
TM
In January 2013, it was announced the
strategic decision by ATS to implement a
new global business system to improve
our ability to effectively manage
our most important resource – our
people. Throughout 2012, multiple
vendors were reviewed to ensure that
the best system was selected, not just
for today but for our future.
Workday was selected as the system for
ATS and it went live globally from the 9th
September 2013.
“Workday” is an Enterprise Business
Management System, consistently rated
one of the best and most innovative
in the industry. Through Workday,
our employees will have the ability to
proactively manage their careers and
professional development.
In addition to this the deployment of
Workday will provide:
• Self-service capabilities for
managers and employees,
eliminating over a dozen
disconnected systems
• Greater insight for managers
to drive business results
• More robust, timely reporting
capabilities with information in
the hands of decision makers
• Cloud-based storage with
24 x 7 availability
09
Initial training for employees on the
new system took place between the 26th
August 2013 and the 6th September 2013
and we want to thank everyone for their
participation. During September and
the beginning of October, training will be
supported with individual coaching sessions
where required and weekly tasks will be
issued with instruction sheets on how to
complete processes within Workday. First
week training focused on logging onto the
system and updating holidays for 2013.
The Change Champions at each site
available to support employees with
Workday are as follows:
• Brierley Hill – Amy Nutting
• Wolverhampton – Emily Mathews
• Havant – Ross Tolliday
• Titchfield – Karen Mattingly and Mike Ford
We would like to thank the Change
Champions for their contributions and
support of this project.
Pictured leftGemma Turner ATS Human Resources Manager
10
Recruitment ATS has set a goal to be a 110 million dollar
business by 2023, and to achieve this we
need to attract over 1,000 employees. To
enable us to attract and recruit the best
possible talent to complement our existing
teams we decided to appoint our first
Recruitment Manager, Anna Prince in August
2013. Historically ATS has relied on external
recruitment agencies and bringing Anna on
board is a first step towards a more integrated
approach to resourcing our business.
Anna has extensive recruitment experience
and she will concentrate on implementing
and delivering a UK specific recruitment
strategy. Raising the profile of the ATS brand
within jobseekers will be an important
feature of her role.
Anna Prince - Recruitment Manager
By approaching recruitment proactively
through understanding our business
and using modern recruitment tools,
techniques and social media Anna will
work on creating talent pools across the
UK. This will add value to our customers
eliminating their recruitment challenges
in terms of time, cost and the risks
involved, as ATS will be in contract with
the right people with the right skills to
support existing sites and to prepare in
other areas as ATS expands.
Enhanceprocesses
.
A note from Anna “For me ATS ticks all the boxes.
I’m delighted to have joined ATS at this
exciting stage and I’m looking forward
to be part of its growth. Getting
Recruitment right, especially when
adding to existing teams, is crucial.
I am interested in your views and any
ideas you have for filling our vacancies
and streamlining our processes and
would be happy to hear from you.”
You can contact Anna on the
following details:
Email: aprince@advancedtech.com Phone: 01536 311654
11
£1000 BONUS Recommend a friend and get £500 when they start employment with ATS and £500 after their first six months Terms: Payment is on completion of
the probationary period.
12
Drivinginn vation
eFactory Connect
ATS eFactory Connect provides a 24/7 call centre for ATS
Technicians, allowing them to dial-up to live maintenance specialists
that can provide assistance on a wide variety of technical and
maintenance related tasks.
The purpose of the programme is to provide site technicians an
additional technical resource to assist in developing solutions.
The programme has already demonstrated enormous benefits in
reducing downtime, minimising maintenance costs, and as a
result a benefit to our customers.
e100,000
manufacturingassets
13
eFACTORYCONNECT
Watch here
400MajorBrands
eFactory Connect can help with…
• Troubleshooting
• Researching machine specific procedures
• Finding Machine Documentation
We are encouraging technicians to call eFactory Connect anytime
a site needs help with any maintenance related issues that they are
unable to resolve immediately; during the troubleshooting/repair
process; and always before calling the OEM.
The provision of this service will reduce costs for our customer as we will
reduce the reliance on the OEM’s. We will improve the speed of fault
resolution through immediate and responsive advice. It will also help the
site improve its performance metrics through more efficient tracking.
14
During June Eaton asked ATS to support
them on 2 safety projects which had been
instructed by the Global Eaton H&S team.
The first was a LOTO identification project
where we needed to document and
highlight the LOTO procedure on all of the
machines. The second was to install tamper
proof screws to all covers and guards. The
onsite team did not have the resource to
complete these projects in a reasonable
time, so we recruited a Project Engineer to
support these projects.
Richard Aylen joined and from day one has
demonstrated leadership in driving safety
and delivering these projects. Both projects
were completed on time and in budget to
the great delight of the customer.
Due to the success of these 2 projects, we
have now been asked to undertake further
projects on behalf of the customer.
Richard Aylen - Project EngineerAwarded by Rick Lyford -
Eaton H&S Manager
Richard was awarded a best practise
recognition award by Rick Lyford (the
Eaton H&S Manager) for his consistent
high levels of safety. Richard clearly
demonstrates what it means to Live Safety.
Richard Aylen Best Practice award
Demonstrate leadership
15
A 3 day Predictive Analysis Initiative
was held at Eaton Havant to support
the Health Assessment which had
been carried out on 8 key machines.
The event was used to analyse the 8
machines using both thermal imaging
and Ultrasound equipment in order
to improve machine efficiency and
eliminate energy lost through air leaks.
11 significant air leaks were located and
repaired during the event, with a total
air loss reduction of more than 63 CFM.
6 issues were detected and investigated
through Thermal analysis, 1 of which was
raised as an urgent W/O.
The event not only demonstrated
the power of predictive maintenance,
but also achieved customer savings
of £24,363.86.
Predictive Analysis Initiative
16
1YR Service award
Congratulations Binh La – Desk Side Technical Engineer
at Church Crookham for achieving his 1 year service award.
SERVICE
awards
3YRS Service award
Congratulations Paul Setterfield – Senior Technician
at Havant, for achieving his 3 year service award.
17
Stefan Korn Eaton HavantCongratulations to Stefan Korn, Technician
at Havant, for winning cost saving of the
month. Stefan was contacted by a US
colleague asking for help with translating
a German machine document. The
document was 70 pages long and required
translation into English as quickly as possible.
An internet search revealed quotations
ranging from £30 to £70 per page
depending on the speed and quality of
the document. Stefan downloaded the 70
page document on to his own computer,
printed it off and translated the entire
document before returning the scanned
document the following day. All the work
Stefan carried out was done during his own
time using his own computer. Not only has
Stefan delivered an excellent cost saving to
the company, but he delivered results and
demonstrated leadership.
COST SAVING OF THE MONTH awards
Stefan Korn - Technician at Havant is awarded by Andrew Purchase
18
ATS Global
Due to an 85% three year growth rate,
Advanced Technology Services continues
to move up the leaderboard of America’s
fastest growing companies.
The list represents the most comprehensive
look at the most important segment of
the economy - America’s independent
entrepreneurs.
ATS joined the ranks of the top 5000 best
performing businesses in 2011 and has
continued its success, rising this year in the
listings. Since 2011, the company has also
added over 1,144 jobs, bringing its current
staff totals to 2,999 employees.
According to Jeff Owens, President of ATS,
“Our considerable growth is due to
two drivers in our business; the need for
manufacturers to increase the performance
and efficiency of production assets, and
the new technology that ATS has brought to
manufacturing.
The US success comes soon after the UK
division achieved a similar accolade in the
UK’s Best Companies Ones to Watch List that
also recognises high growth and dynamic
organisations. Derek Hill of ATS UK commented
that “It is our commitment to building and
delivering value for our clients which continues
to drive our success around the world.
Advanced Technology Services Achieves Fastest Growing Company Accolade from Forbes!
19
CONTINUOUSIMPROVEMENT
Live SafetyDelight CustomersDevelop PeopleEnhance ProcessesDrive InnovationNurture RelationshipsDemonstrate LeadershipDeliver Results
CULTURALCOMMITMENT
A Way of Business, A Way of Life.
£500 BONUS is waiting for you Did you know that there is a £500 bonus
available to all staff for the successful
introduction of new business?
So if you have a contact in another
manufacturing company that you
believe would benefit from working with
ATS, simply contact Keith Edmonds on
kedmonds@advancedtech.com
www.advancedtech.com
Advanced Technology Services UK LtdUnit 4 BeechwoodCherry Hall RoadKettering Business ParkKetteringNorthamptonshireNN14 1UE
Phone: +44 (0)1536 311650
Email: info@advancedtech.com
Key Contacts
Managing DirectorDerek Hilldjhill@advancedtech.com
Sales & Marketing Keith Edmondskedmonds@advancedtech.com
Continuous ImprovementSteve McCarthysmccarth@advancedtech.com
Human ResourcesGemma TurnerGturner@advancedtech.com+44 (0) 1536 311657 - Direct+44 (0) 7527 289917 - Mobile+44 (0) 1536 416965 - Fax